How It’s Made Manufacturing Electric Cables

The first step in the cable manufacturing process is drawing. Copper bars received from suppliers are too thick for use in flexible wires, so they will have to be reduced to the required diameter. To do this, they go through a series of shrinking dice. Copper wires will emerge after reaching the desired diameter. The wires then pass through annealing where they are refined for better electrical conductivity. Once completed, the wires are tied to a metal coil.
The next step after drawing is the wire bench. This's where the copper wires are twisted together to form a cable. The number of twisted wires simultaneously determines the nominal cross-sectional area of ​​the cable. Connecting a series of thin cables provides more flexibility than solid cables of the same size.
Stranding is basically like bundling; The only difference is that the wiring refers to the rotation of the conducting wires, while the bench is reserved for bare copper wires. For certain types of bungee cords, this is where the insulated wires are twisted with a cotton thread before going through the final extrusion process.
Emission is a process in which bare copper wires are insulated. Depending on product requirements, cables may have to undergo several extrusion stages, for example if the cables require an additional layer of insulation.
The final stage of manufacturing involves coiling and cutting the cables to the desired packaging length. The cables can be packed on individual drums or coils, then wrapped and labeled and the pending shipment can be secured.
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