I. Information Related to the Product Itself
(I) Specification Parameters
As a 4-core cross-linked polyethylene
Insulated power cable, the 4c
XLPE Cable has a wide range of specifications to choose from, with common ones being 70mm², 95mm², 120mm², 150mm², 185mm², and 300mm².
In terms of current-carrying capacity, there are obvious differences among cables of different specifications. The current-carrying capacity of a
70mm² Cable is usually around 140-180A; that of a 95mm² cable is approximately 180-230A; a 120mm² cable can reach a current-carrying capacity of 230-280A; a 150mm² cable has a current-carrying capacity of about 280-340A; an 185mm² cable has a current-carrying capacity of around 340-400A; and a 300mm² cable can achieve a current-carrying capacity of 400-500A. These current-carrying capacity data are obtained under standard environmental conditions. If the actual operating environment temperature is relatively high, such as exceeding 30℃, or the cable is laid in a way that is not conducive to heat dissipation like through a pipe, the current-carrying capacity will decrease, and a correction factor of about 0.8-0.9 is generally required.
In terms of cable outer diameter, the outer diameter of a 4c XLPE cable with 70mm² is approximately 35-40mm; that of 95mm² is about 40-45mm; 120mm² is around 45-50mm; 150mm² is roughly 50-55mm; 185mm² is about 55-60mm; and 300mm² is in the range of 65-70mm. Different manufacturers may have slight fluctuations in outer diameter due to differences in process details, but they are all within a reasonable range.
In addition, the rated voltage of this cable is generally 0.6/1kV and above, which can meet the voltage requirements of medium and high-voltage power transmission. The DC resistance of the conductor also has strict standards. Taking
Copper Conductors as an example, the DC resistance of a 70mm² conductor at 20℃ shall not be greater than 0.268Ω/km; 95mm² shall not be greater than 0.193Ω/km; 120mm² shall not be greater than 0.153Ω/km; 150mm² shall not be greater than 0.124Ω/km; 185mm² shall not be greater than 0.0991Ω/km; and 300mm² shall not be greater than 0.0628Ω/km, ensuring the efficiency of current transmission.
(II) Characteristic Applications
The 4c XLPE cable plays an important role in various medium and high-voltage power transmission scenarios by virtue of its own characteristics, and cables of different specifications have their own focuses in applicable scenarios.
Cables of 70-120mm² have moderate current-carrying capacity and are ideal for medium-power scenarios. In small factory production lines, such as some light processing equipment like small lathes and milling machines, their total power is relatively moderate. 70-120mm² cables can stably supply power to these equipment, ensuring the continuous operation of the production line. The main unit and related auxiliary equipment of the central air-conditioning system in shopping malls have relatively large power, but 70-120mm² cables are sufficient to meet their power transmission needs, ensuring that the air-conditioning operates normally in hot summer or cold winter and providing a comfortable environment for customers. In addition, the distribution trunk lines of small and medium-sized office buildings also often choose cables within this specification range, which can meet the electricity needs of office equipment and lighting in the building.
Cables of 150-300mm² have larger current-carrying capacity and are suitable for high-power power transmission scenarios. The distribution trunk lines of industrial parks are responsible for the power transmission tasks of many enterprises in the entire park, with a large power load. 150-300mm² cables can efficiently distribute power to various enterprises, ensuring the stable production power supply of the park. The outgoing lines of the transformer and distribution room in large buildings need to transmit high-voltage electricity to various areas of the building after conversion. 300mm² cables can be used in large buildings with extremely large power loads, such as super high-rise office buildings and large commercial complexes; 150-185mm² are suitable for large buildings with slightly smaller scales but still large power demands. In addition, the power supply of some large industrial equipment, such as large compressors and large motors, cannot do without these large-specification cables.
The 4-core design is a major feature of this cable, which can transmit three-phase electricity and neutral wire at the same time, perfectly adapting to three-phase power equipment. In the industrial field, three-phase electric motors, three-phase water pumps and other equipment generally use three-phase electricity. The 4-core design of the 4c XLPE cable can directly supply power to these equipment without additional laying of neutral
Wire Cables, simplifying the wiring process and reducing the probability of line faults.
(III) Material and Style
The material selection of the 4c XLPE cable takes both performance and practicality into account, and the style design is also in line with the needs of power transmission.
In terms of materials, the insulation layer is made of cross-linked polyethylene (XLPE), which is a polyethylene material subjected to cross-linking treatment. It has excellent electrical insulation performance and high insulation resistance, which can effectively prevent current leakage and ensure the safety of power transmission. At the same time, XLPE has excellent temperature resistance, with a long-term operating temperature of up to 90℃, and can withstand higher temperatures during short-term overload, which enables the cable to work stably during peak electricity consumption. It also has strong mechanical strength, which can resist certain external impact and extrusion, prolonging the service life of the cable.
The conductor is usually made of high-purity copper or aluminum.
Copper Conductors have good electrical conductivity and high conductivity, with small transmission loss, and are the mainstream choice;
Aluminum Conductors have relatively low cost and light weight, and are also used in some scenarios where cost is sensitive and laying conditions permit. The surface of the conductor is generally annealed to increase
Flexibility for easy laying.
The sheath material is mostly polyvinyl chloride (PVC) or polyethylene (PE).
PVC Sheath has good corrosion resistance, wear resistance and flame retardancy, and is suitable for most ordinary environments; PE sheath has better flexibility and excellent low-temperature resistance, and is more advantageous in cold areas or scenarios with low-temperature requirements.
In terms of style, the 4c XLPE cable has a 4-core structure, with cores twisted together and wrapped with an insulation layer and a sheath outside. The overall shape is round, which is convenient for winding and laying. The color of the cable is usually dark colors such as black or gray. On the one hand, it can reduce the temperature increase caused by direct sunlight. On the other hand, it can better adapt to the appearance requirements of outdoor or industrial environments. The surface of some cables will be printed with marks such as model, specification, rated voltage and manufacturer for easy identification and traceability.
(IV) Production Process
The production process of 4c XLPE cable is rigorous and complex, and each step has an important impact on product quality.
First is conductor manufacturing. High-purity copper rods or aluminum rods are selected and drawn into single wires of the required diameter through a wire drawing machine. During the wire drawing process, the drawing speed and die precision should be controlled to ensure uniform diameter of the single wire. After that, multiple single wires are stranded, and the stranding method is regular stranding to ensure stable and round conductor structure. When stranding, the stranding pitch should be controlled. Too large a pitch will affect the flexibility of the conductor, and too small a pitch will increase production difficulty and cost.
Next is insulation extrusion. Cross-linked polyethylene material is used, and it is uniformly coated on the surface of the conductor through an extruder to form an insulation layer. During the extrusion process, the extrusion temperature should be accurately controlled, generally around 120-150℃. Too high a temperature will cause material decomposition, and too low a temperature will result in insufficient density of the insulation layer. The thickness of the insulation layer must strictly meet the standards, and the deviation shall not exceed the specified range to ensure insulation performance.
Then is cross-linking treatment, which is a key step in the production of XLPE cables. Common cross-linking methods include chemical cross-linking and physical cross-linking (irradiation cross-linking). Chemical cross-linking is to add a cross-linking agent to the XLPE material. Under high temperature and high pressure conditions, the cross-linking agent decomposes to generate free radicals, making the polyethylene molecules form a three-dimensional network structure; irradiation cross-linking uses radiation sources such as electron beams to irradiate the insulation layer to induce molecular cross-linking. The performance of XLPE after cross-linking is significantly improved.
After that, the cabling process is carried out, in which 4
Insulated Wire cores are stranded into a cable according to a certain stranding method. When stranding, fillers need to be filled between the cores to make the cable round and play a buffering and protective role. The filling material is usually polypropylene rope, etc. After cabling, a layer of non-woven fabric or film may be wrapped to enhance the structural stability of the cable.
Finally, the sheath is extruded. The sheath material (PVC or PE) is coated on the outside of the cabled core through an extruder. The extrusion parameters also need to be strictly controlled to ensure uniform thickness and smooth surface of the sheath. After extrusion, the cable is cooled and shaped in a cooling water tank, and then undergoes processes such as printing and take-up.
During the production process, each process has quality inspection links, such as conductor diameter inspection, insulation thickness inspection, cross-linking degree inspection, etc., to ensure that the products meet relevant standards.
II. General Product Information
(I) Packaging
The packaging of 4c XLPE cable is designed to protect the cable from damage during storage and transportation, and at the same time facilitate handling and management.
For long-length cables, wooden reels are usually used for packaging. The wooden reels are made of high-quality wood, with sufficient strength and stability to bear the weight of the cable. The cable is neatly wound on the wooden reel, and the tension should be controlled during the winding process to avoid cable deformation due to over-tightening or loosening due to over-loosening. Both sides of the wooden reel are equipped with baffles to prevent the cable from slipping off. The wooden reel will be marked with information such as cable model, specification, length, weight, manufacturer and production date for easy identification. The surface of the cable will be wrapped with plastic film to prevent dust and moisture from entering. For cables with PVC sheaths, it can also avoid sheath aging caused by direct sunlight.
Short-length cables may be packaged with cable reels or cartons. Cable reels are generally made of plastic, which is lightweight and corrosion-resistant, suitable for packaging shorter-length cables. Carton packaging is suitable for shorter samples or small batches of cables. Foam or soft materials will be placed inside as buffers to prevent cables from colliding with each other and being damaged during transportation. Product-related information is also printed on the carton.
Packaging must meet transportation and storage standards. Cables packaged with wooden reels should ensure that the wooden reels are not loose or damaged; carton packaging should be tightly sealed. At the same time, packaging materials must meet environmental protection requirements and be recyclable.
(II) Transportation
The transportation of 4c XLPE cables needs to consider safety and efficiency to ensure that the cables are delivered to the destination in good condition.
The transportation method is selected according to factors such as transportation distance and quantity. Trucks are generally used for short-distance transportation, which has high flexibility and can be directly delivered to the customer's designated location. For long-distance transportation with a large quantity, railway transportation can be chosen. Railway transportation has good stability and is less affected by weather, which is suitable for large quantities of cable transportation. For exported products, sea transportation can be used, which has low cost and can transport large-specification and long-length cables, but the transportation time is relatively long.
There are many precautions during transportation. Cables should be placed flat during transportation, and inversion or tilting is strictly prohibited to prevent the cables from slipping off the wooden reels. When loading, the wooden reels should be fixed. Steel wire ropes or straps can be used to fix the wooden reels on the transport vehicle to avoid shaking and collision of the wooden reels during transportation. Transport vehicles should drive smoothly, avoiding sudden braking and sharp turns to reduce the impact on the cables.
During loading and unloading, special hoisting equipment such as forklifts and cranes must be used, and manual dragging of cables is strictly prohibited. When hoisting, attention should be paid to the hoisting position to avoid damaging the cables or wooden reels. When transporting in rainy days, the cables must be completely covered with rainproof cloth to prevent the cables from getting damp. When transporting in high-temperature weather, try to avoid the cables being exposed to sunlight for a long time, and choose to transport in the morning and evening or take sunshade measures.
Good cargo tracking should be done during transportation to keep abreast of the transportation status of the cables and ensure on-time delivery. If cable damage occurs during transportation, communication should be conducted with relevant parties in a timely manner for proper handling.
(III) Shipment
The shipment process of 4c XLPE cables is standardized and orderly to ensure that products are delivered to customers accurately and timely.
Order confirmation is the first step of shipment. After receiving a customer's order, the sales staff will recheck the cable model, specification, quantity, delivery address, delivery time and other information with the customer to ensure correctness. At the same time, confirm the customer's payment status and collect the payment or advance payment according to the payment method and proportion agreed in the contract.
In the stock preparation link, warehouse managers retrieve the corresponding cables from the inventory according to the order information. If the inventory is insufficient, the production department is promptly notified to arrange production to ensure that the stock preparation is completed within the agreed delivery time. During the stock preparation process, a preliminary inspection of the cables should be carried out to check whether the packaging is intact and the marks are clear.
Outgoing inspection is the key to ensuring the quality of shipment. Quality inspectors conduct a comprehensive inspection of the cables to be shipped, including appearance inspection, length measurement, and spot check of insulation performance. The appearance inspection mainly checks whether the cable sheath is damaged or scratched and whether the insulation layer is uniform; the length measurement must meet the order requirements, and the error is within the allowable range; the spot check of insulation performance can be carried out by insulation resistance test to ensure that the cable insulation performance meets the standards. After passing the inspection, an inspection report is issued.
When arranging transportation, a suitable transportation method and transportation company are selected according to the customer's address and cable conditions, and a transportation contract is signed to clarify the rights and obligations of both parties. After loading the cables onto the transport vehicle, a shipment notice is sent to the customer, informing the customer of the transport vehicle information (license plate number, driver's contact information) and estimated arrival time to facilitate the customer's preparation for receiving the goods. After shipment, the goods will be tracked, and the transportation status of the goods will be obtained through the transportation company and fed back to the customer in a timely manner. After the goods arrive, the customer is reminded to receive and inspect the goods in a timely manner.
(IV) Samples
To help customers understand the performance and quality of 4c XLPE cables, the company provides sample services with a simple and efficient process.
Customers can apply for samples through phone calls, emails, online customer service, etc., stating the required cable models, specifications and other information, and providing the receiving address and contact information. After receiving the sample application, the company will review it within 1-2 working days to confirm the rationality of the customer's needs.
In terms of sample preparation, the length of the sample is generally 1-2 meters, which can meet the customer's needs for checking the appearance, material and structure of the cable. Samples will be cut from qualified products to ensure consistent quality with bulk products. The surface of the sample will be marked with model, specification and other information for easy identification by customers.
Samples are usually sent by express, and reputable and fast express companies are selected. Before sending, the samples are properly packaged to prevent damage during transportation. At the same time, product manuals, sample inspection reports and other materials are attached to help customers fully understand the samples. The company will promptly inform the customer of the express waybill number to facilitate the customer to track the sample logistics information.
Samples are generally provided free of charge, but the customer may need to bear the express fee, which can also be negotiated according to the customer's situation. After receiving the samples, if customers have any questions, the company's technical personnel will answer them in a timely manner and provide professional consulting services.
(V) After-sales Service
The company attaches great importance to the after-sales service of 4c XLPE cables and provides customers with comprehensive support and guarantees.
In terms of quality assurance, cable products provide a certain warranty period, usually 1-2 years, calculated from the date the customer receives the goods. Within the warranty period, if the cable fails due to its own quality problems, such as insulation layer breakdown and conductor breakage, the company will provide free repair or replacement services for the customer. Customers need to provide purchase certificates and fault descriptions, and the company will arrange technical personnel to verify the situation.
Technical support is an important part of after-sales service. The company has a professional technical team that can provide customers with technical guidance on cable selection, laying and installation. When customers encounter technical problems during the use of cables, they can consult by phone, email, etc. Technical personnel will reply within 24 hours and can provide on-site technical services if necessary.
For cable damage caused by non-quality problems, such as man-made damage and improper use, the
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