I. Product - Related Information
(I) Specifications and Parameters
This product is a DC
Copper Core cable, supplied in reels, mainly including two specifications: 4
185+170mm² and 4X240+1X120mm², specially designed for DC power transmission scenarios.
In terms of structural specifications, it adopts a 4 +
1 Core structure, which is scientifically and reasonably designed. The 4 main cores are used for power transmission, and 1 auxiliary core is specially used for grounding protection, which can ensure electrical safety while transmitting power. In the 4
185+170mm² specification, the cross - sectional area of each of the 4 main cores is 185mm², and the cross - sectional area of the auxiliary core is 70mm²; in the 4X240+1X120mm² specification, the cross - sectional area of the 4 main cores is 240mm², and the cross - sectional area of the auxiliary core is 120mm².
Different specifications have different current - carrying capacities. The current - carrying capacity of 4185+170mm² is about 350 - 400A, and that of 4X240+1X120mm² is about 450 - 500A. The large current - carrying capacity enables them to meet the power needs of DC equipment with different powers. Cables supplied in reels are usually 50 meters or 100 meters per reel, which can be selected according to the customer's actual laying needs, and in some cases, special length customization can also be accepted.
The DC resistance of the cable meets relevant standards. The DC resistance per kilometer of 4185+170mm² is not more than 0.103Ω, and that of 4X240+1X120mm² is not more than 0.078Ω. The low resistance ensures the efficiency of power transmission.
With its own specifications and performance advantages, this cable has a wide range of application scenarios. In the field of new energy energy storage, large - scale energy storage systems need stable DC power transmission, and cables of 4185+170mm² specification can meet their needs. When the energy storage system is in operation, the power transmission is large and lasts for a long time. The high current - carrying capacity and low resistance characteristics of the cable can ensure efficient power transmission, and the grounding protection function can also improve the system safety.
DC charging pile clusters have high requirements for power transmission, especially during peak hours, when multiple charging piles work at the same time, and the power demand is large. Cables of 4X240+1X120mm² specification are suitable for such higher - power scenarios. It can stably transmit power to the charging pile cluster to ensure a smooth charging process.
In terms of industrial DC motors, for some high - power DC motors, such as drive motors used in heavy machinery, 4
185+170mm² Cables can be used as their power transmission lines; for ultra - high - power industrial DC motors, 4X240+1X120mm² cables can better meet the needs. In addition, this cable can also play an important role in the DC power supply system of rail transit such as subways and light rails, and its stable transmission performance can ensure the normal operation of rail transit.
(III) Material and Style
Conductor Material
The
Cable Conductor is made of high - purity copper with a purity of more than 99.9%. High - purity copper has excellent conductivity, which can minimize losses during power transmission and improve transmission efficiency. This is particularly important for DC power transmission, which can avoid energy waste caused by excessive resistance.
At the same time, copper has good mechanical strength and ductility. The mechanical strength enables the cable to withstand conventional external forces such as tension and pressure during laying and use, and is not easy to break; the ductility enables the cable to not damage the conductor structure when bent to a certain extent, ensuring the continuity of power transmission.
Insulation Layer Material
The insulation layer is made of
Insulation Material specially designed for DC transmission, which has excellent DC voltage resistance. Under the action of DC electric field, it can effectively inhibit partial discharge, which is an important cause of insulation aging. Therefore, the insulation layer can significantly extend the service life of the cable.
In addition, the insulation material also has good temperature resistance, and can work stably in the environment of - 40℃ to 105℃, adapting to temperature changes in different regions and scenarios. It also has strong chemical stability and is not easy to be eroded by chemical substances in the surrounding environment, ensuring long - term stable insulation performance.
Sheath Layer Material
The sheath layer is made of wear - resistant special materials, which have high hardness and can resist friction during laying, such as friction with the inner wall of the pipe during pipe laying, and external forces such as collisions that may be encountered during use, so as to protect the internal conductor and insulation layer from damage.
The sheath layer also has a certain flame - retardant performance. When encountering an open flame, it can slow down the burning speed and reduce the risk of fire. At the same time, it has good weather resistance, and can resist the influence of natural factors such as sunlight exposure and wind and rain erosion in the outdoor environment, extending the service life of the cable.
Style Design
The cable is round in shape and has a regular appearance. The 4 main cores and 1 auxiliary core are arranged in an orderly manner in the sheath, with a compact structure and space - saving. Cables of different specifications have obvious differences in diameter. 4X240+1X120mm² has a larger diameter than 4185+170mm², which can be visually distinguished.
The roll - type design is convenient for storage and transportation. Each roll of cable is neatly wound and takes up little space. When in use, it can be cut according to the actual required length, which is convenient and flexible to operate. The color of the cable is usually black, which is not only resistant to dirt, but also can absorb heat to a certain extent, reducing the impact of external temperature on the inside.
(IV) Production Process
Conductor Manufacturing
For conductor manufacturing, high - purity copper raw materials are first strictly screened and tested to ensure that their purity and performance meet the requirements. After that, the copper raw material is made into copper rods through smelting, billet casting and other processes. The quality of copper rods directly affects the performance of subsequent conductors.
The copper rod is drawn into copper wires of the required diameter through wire drawing equipment. During the wire drawing process, the wire drawing speed and mold precision must be precisely controlled to ensure that the diameter of the copper wire is uniform and the surface is smooth. For the main core and auxiliary core of 4185+170mm² and 4X240+1X120mm² specifications, copper wires with corresponding diameters are used respectively.
Subsequently, multiple copper wires are stranded to form a conductor according to a specific stranding method. During stranding, it is necessary to ensure that the copper wires are arranged closely and with uniform tension to enhance the conductivity and mechanical strength of the conductor. After stranding, the conductor is annealed. Through the heating and cooling process, the internal stress of the conductor is eliminated, and its
Flexibility and conductivity are further improved.
Insulation Layer Extrusion
Before extruding the insulation layer, the insulation material needs to be pretreated to remove moisture and impurities to avoid affecting the insulation performance. The treated insulation material is sent to the extruder and melted and plasticized at an appropriate temperature.
The melted insulation material is evenly coated on the surface of the conductor through a special mold to form an insulation layer. During the extrusion process, it is necessary to strictly control the extrusion temperature, speed and pressure to ensure that the insulation layer has a uniform thickness, is closely combined with the conductor, and has no defects such as bubbles and pinholes. For conductors of different specifications, molds of corresponding sizes should be matched to ensure that the thickness of the insulation layer meets the design requirements.
Cabling Process
Cabling is to strand 4 main cores and 1 auxiliary core together according to a certain arrangement order and stranding pitch. During stranding, it is necessary to ensure that each core wire is in the correct position and the tension is consistent to avoid loosening and twisting. During the stranding process, appropriate filling materials can be filled between the core wires to make the cabled cable structure more round and stable and enhance its impact resistance.
After cabling, a preliminary appearance inspection is carried out on the cable to ensure that the core wires are arranged neatly and stranded evenly.
Sheath Extrusion and Finished Product Inspection
When extruding the sheath, the sheath material is added to the extruder, melted and evenly coated on the outer layer of the cabled cable through a mold to form a sheath layer. It is necessary to control the thickness of the sheath layer to ensure that it can effectively protect the internal structure. During the extrusion process, it is necessary to adjust the process parameters according to the cable specifications to ensure that the surface of the sheath layer is smooth and the thickness is uniform.
The finished product inspection link is crucial. The appearance, size, insulation performance, conductivity and other aspects of the cable must be fully inspected. The appearance inspection checks whether the sheath is smooth and has no damage; the size measurement checks whether the conductor cross - sectional area, insulation layer and sheath layer thickness meet the specifications; the insulation performance test is carried out through voltage withstand test and other methods; the conductivity test detects the DC resistance of the conductor. Only cables that meet all indicators can be packaged in reels.
II. General Product Information
(I) Packaging
Packaging Materials
The cable is packaged in reels, and the packaging materials mainly include wooden reels and plastic films. The wooden reel has high strength and stability, which can support the cable to keep in a rolled state and prevent deformation during storage and transportation. Cables of 4185+170mm² and 4X240+1X120mm² specifications use wooden reels with corresponding load - bearing capacity respectively.
The outer layer of the cable reel is wrapped with a layer of plastic film, which can effectively prevent moisture and dust and avoid the cable from being polluted by the external environment. For cables that need long - distance transportation, a layer of woven bag is also put over the plastic film. The woven bag has good wear resistance and tensile resistance, which can further protect the cable from damage.
Packaging Methods
When packaging, first wind the cable neatly on the wooden reel. During the winding process, maintain appropriate tension to ensure that the cable is arranged closely and not loose. After winding, wrap the entire cable reel tightly with plastic film, which should be close to the surface of the cable without gaps.
For cables transported over long distances, after putting on the woven bag, fix the woven bag firmly on the wooden reel with a rope. A label is pasted in the obvious position of the package. The label indicates the product name, specification (such as 4185+170mm²), length, production date, batch number, implementation standard and other information, which is convenient for customers to identify and check. At the same time, warning signs such as "Moisture Proof", "Handle with Care" and "Do Not Stack Heavily" are also printed on the label.
(II) Transportation
Transportation Methods
Appropriate transportation methods are selected according to the transportation distance and order quantity. For short - distance transportation (such as surrounding cities), small trucks are usually used. This transportation method is flexible and convenient, can deliver goods quickly, and is suitable for small - batch orders.
For medium - and long - distance transportation with large order quantities, large freight trucks are used, which have a large loading capacity and relatively low transportation costs. For urgent orders, logistics lines or express transportation such as Deppon and SF Express can be chosen. These transportation methods are faster but relatively costly.
Transportation Precautions
During transportation, the cable reel should be placed flat to avoid upright placement to prevent rolling and falling. When loading, there should be an appropriate gap between the cable reels, or they should be separated by partitions to avoid mutual collision and extrusion. When stacking, the stacking height should not be too high. The stacking of 4185+170mm² cable reels should not exceed 3 layers, and that of 4X240+1X120mm² cable reels should not exceed 2 layers to prevent the bottom cable reels from being damaged by pressure.
Transport vehicles should take rainproof and sunproof measures to prevent the cable from being wetted by rain or exposed to the sun. During transportation, drive smoothly and reduce sudden braking and sharp turns to prevent the cable reel from shaking and colliding in the vehicle. At the same time, avoid transporting with corrosive goods and sharp objects to prevent the cable from being polluted and damaged.
(III) Shipment
Shipment Process
After the customer places an order, customer service personnel will check the order information in a timely manner, including product specifications, quantity, receiving address, contact information, etc., to ensure accuracy. After checking, the warehouse is notified to prepare the goods.
Warehouse managers retrieve cable reels of corresponding specifications and quantities from the inventory according to the order information, count and inspect their appearance to confirm that the cable reels are intact and the packaging is complete. After the goods are prepared, the cable reels are transported to the shipping area to prepare for shipment.
Contact the transport company, inform the goods information and shipping requirements, and arrange transport vehicles. When the transport vehicle arrives, load the cable reels onto the vehicle and go through relevant shipping procedures, such as filling in waybills and delivery orders. After shipment, customer service personnel promptly inform the customer of the waybill number, transport company name, estimated arrival time and other information to facilitate the customer to track the logistics.
Shipment Time
When the inventory is sufficient, regular orders (such as no more than 5 reels per specification) are generally shipped within 1 - 2 working days after the customer places the order. If the order quantity is large (such as more than 10 reels per specification), it is necessary to prepare, sort and package the goods, and the shipment time will be extended to 2 - 3 working days.
If customers need to customize cables of special lengths, the production cycle will increase accordingly, generally 5 - 7 working days. The specific shipment time will be determined according to the production progress. In case of special circumstances such as holidays and bad weather, the shipment time may be delayed, and customer service personnel will communicate with the customer in advance to explain the reason and negotiate a solution.
(IV) Samples
Sample Provision
To help customers understand product quality and performance, the company provides sample services. Customers can put forward sample requirements to sales personnel and specify the specifications of the required samples. The company provides samples of 4185+170mm² and 4X240+1X120mm² specifications free of charge, and the length of the samples is generally 1 - 2 meters.
The material and process of the samples are exactly the same as those of mass - produced products, which can truly reflect the actual performance of the products. The transportation cost of the samples is borne by the customer, and the customer can choose to pay the freight by themselves or be collected by the company.
Sample Delivery
After the samples are prepared, the staff simply package the samples, usually wrapped with a hard paper tube and covered with a plastic bag to prevent damage during transportation. The sample specification, company name and contact information are marked on the package.
Choose a reliable express delivery method, such as SF Express and Yuantong Express. After the samples are sent, the sales personnel promptly inform the customer of the express waybill number, and the customer can query the logistics information of the samples through the express waybill number. Domestic samples are generally delivered within 1 - 4 working days, and it may take 5 - 7 working days in remote areas.
(V) After - sales Service
Quality Assurance
The company provides quality assurance for this DC copper
Core Cable product, with a warranty period of 18 months from the date when the customer receives the product and accepts it. During the warranty period, if the product fails due to its own quality problems (such as conductor breakage, insulation layer aging and damage and other non - human factors), the company is responsible for providing customers with free replacement of new products or maintenance.
If the product failure is caused by improper use by the customer (such as use beyond the current - carrying capacity, wrong laying method, external impact, etc.) or natural loss, the company does not assume the responsibility of free warranty, but can provide paid maintenance services.
After - sales Service Process
If a customer finds a product quality problem during use, they can feedback through the company's customer service phone, email, online customer service and other channels. After receiving the feedback, customer service personnel will record customer information, product specifications, purchase time, fault phenomena and other contents in detail, and arrange technical personnel to connect within 24 hours.
Technical personnel communicate with customers to further understand the fault situation, and if necessary, ask customers to provide photos or videos of the fault site. After verification, determine the cause and responsibility of the fault. If it is a quality problem, negotiate a solution (replacement or repair) with the customer and complete it within the agreed time; if it is not a quality problem, explain the reason to the customer, and provide corresponding treatment suggestions and charging standards, and carry out treatment after the customer agrees.
Technical Support
The company has a professional technical team to provide customers with all - round technical support. When customers purchase products, technical personnel recommend cables of appropriate specifications according to factors such as the customer's use scenario and power demand; when customers encounter technical problems during cable laying and installation, they can consult technical personnel at any time, and technical personnel provide professional guidance, such as bending radius requirements
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