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What processes are involved in the development and production of aluminium cables?
2015-08-27
Aluminium alloy rod continuous casting and rolling process
Excellent aluminium alloy conductor rod is a decisive element in the electrical and mechanical properties of aluminium alloy cables, stable production of aluminium alloy rods to meet the requirements mainly from the following links.
1)Calculate and determine the amount of aluminium ingot, intermediate alloy and additives, sequentially add material in its melting into the holding furnace, add additives refining and mixing, while sampling and analysing different points in the furnace, and make corresponding adjustments when needed.
2) Because of the high temperature after alloy refining, aluminium liquid crystallization is more difficult, pay attention to adjust the cooling water pressure at any time, keep the crystallization wheel clean, in order to smooth crystallization of aluminium liquid forming.
3) Rolling strictly control the tensile strength and elongation of the aluminium rod, to facilitate the subsequent pulling and stranding process of tightening. Because the aluminium rod has internal stress to be stored for more than 48 hours before use.
Conductor pressing process
Aluminium alloy cable conductor using 8000 series aluminium alloy, using a special tightening process, in order to control the outer diameter of the cable, the general tightening coefficient of 0.92 or more, through the maximum limit of the tightening, to make up for the lack of aluminium alloy in the volume of the conductivity, so that the stranded conductor core such as a solid conductor in general, a significant reduction in the outer diameter of the wire core, to improve electrical conductivity, taking into account the hardness of the aluminium alloy material, in the tightening and annealing process, be sure to select the appropriate conductor core. Considering the hardness of the aluminium alloy material, in the process of pressing and annealing, we must choose the suitable mould, stranding speed and annealing temperature to ensure the uniform shape of the aluminium alloy conductor and excellent pressing effect. In order to achieve better compression effect, according to the core cross-section of different equipment for stranding compression, small cross-section of the core using tube stranding machine; medium cross-section of the core using roll-forming stranding machine; large cross-section of the core using frame stranding machine.
Conductor annealing process
Conductor annealing to follow three principles: annealing temperature, annealing time, the amount of loading disc.
Annealing temperature: annealing temperature should be higher than the temperature of complete recrystallisation, but lower than the temperature of excessive grain growth.
Annealing time: in order to ensure that the internal and external conductor monofilament are fully recrystallised under the conditions of the complete recrystallization, as far as possible to take the lower limit of the time, in order to improve production efficiency and reduce power consumption.
The amount of loading disc: the size of the conductor loading disc amount of conductor annealing performance has a direct impact, try to choose the amount of loading disc is similar to the annealing treatment, try to avoid annealing during the day, the amount of loading furnace is best to load a full.
Aluminium alloy with interlocking armouring process
Interlocking armouring is a single-layer armouring structure, which is characterized by aluminum alloy belt pre-pressing into "S" shape surface, with the cable core as the centre of the rotating wrapping outside the cable core, each section of the "S" shape surface of its own interlocking, forming a layer of self-locking armouring layer. The armouring belt adopts 5000 series aluminium alloy belt, which has good forming and processing performance, high strength, especially high fatigue strength, good corrosion resistance and weldability, but poor cutting performance. In the armouring process in addition to the equipment factors, alloy belt material properties, section geometry, size, buckling gap is the key to the technology, requires armouring pitch consistent, even and flat, no cracking and no disengagement, and can withstand armouring-related testing. Mould design and processing, mould station and tension adjustment, as well as the operator's experience is very important.