Manufacturing Process of Extension Power Cord

The factory produces power cords every day, and the power cords need more than 100,000 meters and 50,000 plugs a day. With such huge production data, the production process must be very stable and mature. After continuous exploration and research, our company has been recognized by the European VDE certification body, the national standard CCC certification body, the American UL certification body, the British BS certification body, and the Australian SAA certification body. The power cord plug has matured, let’s introduce the manufacturing process:

Copper and aluminum monofilament drawing for power cord
Copper and aluminum rods commonly used in power cords, at room temperature, use a wire drawing machine to pass through one or several die holes of the drawing die to reduce the cross section, increase the length, and improve the strength. Wire drawing is the first process of each wire and cable company, and the main process parameter of wire drawing is the mold clamping technology.
2. Power cord monofilament annealing
When the copper and aluminum monofilaments are heated to a certain temperature, the toughness of the monofilaments is improved and the strength of the monofilaments is reduced by means of recrystallization, so as to meet the requirements of electric wires and cables for conductive cores. The key to the annealing process is to eliminate the oxidation of the copper wire.
3. Stranding of power cord conductors
In order to improve the flexibility of the power cord and facilitate laying and installation, the conductive core is twisted with multiple monofilaments. From the stranding method of the conductive core, it can be divided into regular stranding and irregular stranding. Non-regular stranding is divided into beam stranding, concentric stranding, special stranding, etc. In order to reduce the occupied area of the wire and reduce the geometric size of the power cord, the compact method is also used in the stranded conductor, so that the ordinary circle is mutated into a semicircle, fan shape, tile shape or tight circle. This type of conductor is mainly used on power lines.
Power cord insulation wrapped extrusion
Plastic power cords mainly use extruded solid insulation. The main technical requirements for plastic insulation extrusion:
1) The eccentricity of the wire: The eccentric value of the extruded insulation thickness is the main indicator of the degree of extrusion workmanship. Most of the product structure size and its deflection value are clearly stipulated in the standard.
2) Lubrication of wires: The surface of the extruded insulating layer is required to be lubricated, and there must be no poor quality problems such as rough surface, burnt, and impurities
3) Density of the wire: the cross-section of the extruded insulating layer should be dense and strong, no pinholes visible to the naked eye are allowed, and the existence of air bubbles in the insulating layer should be avoided.
The power cord is cabled

For the multi-core power cord, in order to ensure the formability and reduce the shape of the power cord. Power cords generally need to be twisted into a circle. The mechanism of stranding is similar to that of conductor stranding, because the stranding system has a larger pitch diameter, most of them adopt the non-back twisting method. Cable system technical requirements for power cords: One is to eliminate the twisting of the cable caused by the overturning of the special-shaped insulated core; the other is to prevent the insulation layer from being scratched.
Most cables are also accompanied by the completion of two other processes during cabling: One is filling to make the cable round and stable; the other is binding to ensure that the cable core is not loose after the tube.