How Cables Are Manufactured And Which Cable Quality Control Measures Are Used In Cable Customization?

We are surrounded by different types of electrical cables and wires. Most of us have become so accustomed to their presence in our daily lives so much that we hardly give them any thought.  Considering that life would be difficult without their existence, don’t you think you ought to know how they are manufactured? Which techniques and procedures do electrical cable industries use to manufacture electrical wires and cables?

The process of manufacturing cable is not as complex as you might think. There are only two essential components of any electrical cable, namely a conductor and insulation material. It is important to note that cable manufacturers tend to specialize in producing different types of wires. Conductors and insulation materials used in the cable manufacturing process tend to vary depending on the type of cable made.

Currently, copper is the most commonly used conductor in the cable manufacturing industry. Have you been asking yourself why the number of copper cable suppliers is overwhelmingly high? The answer is quite simple. A considerable proportion of cable manufactures use copper conductors. How exactly are cables manufactured?

First, a raw conductor material such as copper is put through an extrusion machine to create a perfectly shaped wire. The manufacturer uses the wire to construct cable conductors. Once the conductors are wholly built, the insulation material is added on top of the conductor to prevent current loss. Most cable manufacturers use PVC, XLPE, and EPR insulating materials.

Some electrical applications may require custom-made cables because all available pre-made cables cannot satisfy certain specific requirements. Ordinary wires are taken through an extensive customization process that incorporates various precise components needed for the particular task. Logically, any cable customization process is overwhelmingly complex. Consequently, cable manufacturers have to implement several quality control measures to ensure that the cable meets all quality standards.

In most instances, customized cable assemblies transmit high-fidelity signals and mission-critical equipment. The safety, effectiveness, and longevity of any custom cable have grave consequences. Consequently, cable manufacturers have to subject customized wires to a series of rigorous electrical, mechanical and environmental tests to ensure that they meet all quality standards. What are some common cable quality control measures that OEM cable manufacturers or any other manufacturers implement?

A conductor resistance test is often the first and most important quality control measure when dealing with customized cables. Why is this test important? If the conductor resistance surpasses acceptable standards, there is a significant chance that several adverse outcomes will occur. Cable manufacturers implement cable quality control measures such as conductor resistance tests to avoid such unfortunate occurrences.

There several other cable quality control tests that global manufacturers, including UK cable manufacturers, implement. The most common quality tests include;

• Insulation thickness test helps to ensure that the cable can withstand voltage and mechanical stress.
• Sheath thickness test helps to verify compliance with specifications concerning mechanical stress.
• voltage test is to ensure that the cable does not break down.