Aluminum Cable

Cable manufacturing requires consistent control across conductor processing, insulation extrusion, core assembly, armoring, sheathing, testing, and packaging—each stage affects electrical performance, dimensional consistency, installation behavior, and service reliability.

Raw Material Verification
Incoming materials—aluminum/alloy rod, XLPE/PVC/PE/LSZH compounds, steel/aluminum wire, steel tape, fillers, binding tape, and cable drums—are checked for grade, documentation, surface condition, diameter, weight, batch, color, and storage requirements.

Aluminum Rod Drawing
Aluminum rod is drawn through dies to reduce diameter—controlling wire diameter, surface quality, roundness, elongation, tensile properties, joint quality, cleanliness, and spool winding.

Annealing Where Required
Controlled thermal processing achieves required flexibility, elongation, handling, stranding, and termination properties—temperature, time, and cooling controlled per conductor specification.

Conductor Stranding
Individual wires are stranded together—controlling wire count, diameter, stranding direction, lay length, conductor diameter/roundness, surface smoothness, tension, and joint positioning for stable, extrusion-ready conductors.

Conductor Compaction
Compaction tooling reduces conductor diameter and improves roundness, reducing spaces between strands for more uniform insulation extrusion, smaller overall dimensions, and improved construction stability—compaction ratio must remain within approved design limits.

Conductor Resistance Testing
Resistance is measured and temperature-corrected per nominal cross-section and standard—ensuring electrical compliance even when dimensions appear correct.

Insulation Extrusion
XLPE is extruded continuously—controlling compound cleanliness, extrusion temperature, line speed, insulation thickness (including minimum), eccentricity, surface smoothness, centering, cooling, and curing.

Online Spark Testing
During extrusion, the insulated conductor passes through a spark tester to identify discontinuities or defects—parameters selected by insulation thickness, voltage grade, standard, and internal requirements.

Core Identification
Insulated conductors are identified via insulation colors, printed numbers/letters, longitudinal stripes, or customer markings—must remain visible and consistent; incorrect identification is a significant quality issue.

Core Twisting and Assembly
Multicore cables have insulated conductors twisted together with fillers for shape and stability—controlling core sequence, identification, lay direction/length, filler placement, tension, assembly diameter, and roundness.

Binding Tape Application
Tape is applied around assembled cores with consistent overlap, suitable tension, complete coverage, and compatibility—securing structure without damaging insulation or creating excessive diameter.

Inner Sheath or Bedding Extrusion
Inner sheath is extruded over assembled cores to hold assembly, create smooth armor base, separate cores from armor, improve geometry, and protect during armoring—thickness, eccentricity, surface quality, and diameter are monitored.

Steel Wire or Aluminum Wire Armoring
Armor wires are helically applied—controlling material, wire diameter/count, coverage, lay direction/length, tension, cable diameter, and surface consistency for even, gap-free, damage-free application.

Steel Tape Armoring
One or more metallic tapes are applied—controlling tape width/thickness, overlap, wrapping direction, tension, surface condition, and coverage consistency without damaging underlying layers.

Outer Sheath Extrusion
Outer sheath is extruded over the completed assembly—controlling compound, color, thickness (including minimum), eccentricity, surface quality, overall diameter, printing position, and cooling for smooth, continuous, defect-free finish.

Cable Printing and Meter Marking
Identification is printed during or after extrusion—verifying manufacturer name, designation, rated voltage, conductor size, core count, standard, customer brand, legibility, spacing, meter sequence, and batch identification.

Final Electrical Testing
Finished cables are tested per specification—including conductor resistance, voltage withstand, insulation resistance, partial discharge (where applicable), continuity, and other standard-required tests.

Dimensional Inspection
Dimensions are verified with calibrated equipment—conductor diameter, insulation thickness (including minimum and eccentricity), bedding thickness, armor diameter/wire, sheath thickness (including minimum), overall diameter, and ovality.

Cable Rewinding and Length Measurement
Finished cable is wound onto drums—verifying length, meter markings, drum size/loading direction, bending radius, layering, end protection, and drum weight for even winding.

Packaging and Final Inspection
Before shipment, packed cable is checked for model, drum number, cable length, gross/net weight, end sealing, drum condition, labels, arrows, lifting marks, shipping marks, purchase order, quantity, and required documents—only approved products are released.