PVC Insulated Copper Conductor Flexible Cable: 2× 25mm² , 2× 16mm² and 4 Core Flexible Electronic Cable

Conductor Parameters: Composed of 2 Copper Conductors with a cross-sectional area of 16mm². Each conductor is formed by stranding 80-100 fine Copper Wires with a diameter of 0.15mm-0.2mm, with a stranding pitch of 8mm-10mm. The diameter of a Single Core Conductor is approximately 5.1mm. At 20℃, the DC resistance of a Single Core is ≤1.15Ω/km. The total weight of the 2 conductors is about 160kg per kilometer, and they can withstand a tensile force of ≥6kN.

Insulation Parameters: The insulation layer is made of PVC material, with a thickness of 0.8mm-1.0mm, and the thinnest part is not less than 0.7mm. The insulation resistance is ≥100MΩ·km, the dielectric loss tangent is ≤0.03 (at 50Hz), and the breakdown strength is ≥15kV/mm. The long-term operating temperature ranges from -15℃ to 70℃, and it can withstand a high temperature of 80℃ during short-term overload (within 1 hour).

Sheath Parameters: The sheath is made of PVC material, with a thickness of 0.6mm-0.8mm, an average thickness of ≥0.7mm, and the thinnest part of ≥0.5mm. The tensile strength is ≥12MPa, the elongation at break is ≥150%, and the oxygen index is ≥28, which has certain flame retardant performance.

Overall Parameters: The rated voltage is 300/500V, the overall outer diameter is about 8mm-10mm, the bending radius is ≤5 times the outer diameter (about 40mm-50mm), and the weight per kilometer is about 220kg. At an ambient temperature of 30℃, the current-carrying capacity when laid in air is about 60A-70A, and when laid in a pipe, it is about 50A-60A.

Conductor Parameters: Contains 2 copper conductors with a cross-sectional area of 25mm². Each conductor is formed by stranding 120-150 fine copper wires with a diameter of 0.18mm-0.22mm, with a stranding pitch of 10mm-12mm. The diameter of a single core conductor is approximately 6.4mm. At 20℃, the DC resistance of a single core is ≤0.727Ω/km. The total weight of the 2 conductors is about 250kg per kilometer, and they can withstand a tensile force of ≥8kN.

Insulation Parameters: The PVC Insulation layer has a thickness of 1.0mm-1.2mm, and the thinnest part is ≥0.9mm. The insulation resistance is ≥100MΩ·km, the dielectric loss tangent is ≤0.03 (at 50Hz), and the breakdown strength is ≥15kV/mm. The long-term operating temperature range is -15℃ to 70℃, and it can withstand a high temperature of 80℃ during short-term overload.

Sheath Parameters: The PVC Sheath has a thickness of 0.8mm-1.0mm, an average thickness of ≥0.9mm, and the thinnest part of ≥0.7mm. The tensile strength is ≥12MPa, the elongation at break is ≥150%, and the oxygen index is ≥28.

Overall Parameters: The rated voltage is 450/750V, the overall outer diameter is about 10mm-12mm, the bending radius is ≤6 times the outer diameter (about 60mm-72mm), and the weight per kilometer is about 350kg. At an ambient temperature of 30℃, the current-carrying capacity when laid in air is about 80A-100A, and when laid in a pipe, it is about 70A-85A.

Conductor Parameters: The single core cross-sectional area of the 4 Conductors is usually 0.5mm²-6mm². Taking 2×0.75mm² + 2×0.5mm² as an example, the 0.75mm² conductor is formed by stranding 16 fine copper wires with a diameter of 0.25mm, and the 0.5mm² conductor is formed by stranding 10 fine copper wires with a diameter of 0.25mm, with a stranding pitch of 5mm-8mm. The diameter of the 0.75mm² conductor is about 1.2mm, and the diameter of the 0.5mm² conductor is about 1.0mm. At 20℃, the DC resistance of the 0.75mm² conductor is ≤26Ω/km, and that of the 0.5mm² conductor is ≤40Ω/km. The total weight of the 4 conductors is about 30kg-80kg per kilometer, and they can withstand a tensile force of ≥3kN.

Insulation Parameters: The PVC insulation layer has a thickness of 0.5mm-0.8mm, and the thinnest part is ≥0.4mm. The insulation resistance is ≥100MΩ·km, the dielectric loss tangent is ≤0.03 (at 50Hz), and the breakdown strength is ≥15kV/mm. The long-term operating temperature is -15℃ to 70℃.

Sheath Parameters: The PVC sheath has a thickness of 0.5mm-0.7mm, an average thickness of ≥0.6mm, and the thinnest part of ≥0.4mm. The tensile strength is ≥12MPa, the elongation at break is ≥150%, and the oxygen index is ≥28.

Overall Parameters: The rated voltage is 300/500V, the overall outer diameter is about 8mm-15mm, the bending radius is ≤4 times the outer diameter (about 32mm-60mm), and the weight per kilometer is about 50kg-120kg. At an ambient temperature of 30℃, the current-carrying capacity of the 0.75mm² conductor is about 6A-8A, and that of the 0.5mm² conductor is about 4A-6A.

2×16mm² Cable: Widely used for power connection of industrial robot arms. When the robot performs complex movements such as 360° rotation and telescoping, the cable can follow its flexible movement without being damaged, ensuring the normal operation of the robot. At the same time, it is also suitable for power supply of moving parts in automated production lines, such as the connection of drive motors of conveyors.

2×25mm² Cable: Suitable for large mobile machinery, such as the boom part of concrete pump trucks and the moving mechanism of telescopic conveyors. These equipment require high-power power supply, and their parts move frequently during work. This cable can meet their current-carrying capacity and Flexibility requirements.

4-Core Flexible Electronic Cable: Used for connection between sensors and controllers in intelligent production lines. It not only transmits power to the sensors but also feeds back the signals collected by the sensors to the controllers. The signal transmission attenuation rate is ≤0.5%/km, ensuring the accuracy and stability of data.

2×16mm² and 2×25mm² Cables: Play an important role in temporary power supply for buildings, such as stage lighting equipment and electrical equipment in exhibition booths. Since these scenarios require frequent arrangement and disassembly of lines, the cables are preferred due to their characteristics of easy winding and drag resistance, which can reduce line arrangement time and loss.

4-Core Flexible Electronic Cable: Used for wiring of building intelligent systems, such as the connection between smart home control panels and various electrical appliances, and the line connection of security system cameras, alarms and other equipment. Its small outer diameter and good flexibility make it suitable for laying in narrow spaces such as walls and floors.

4-Core Flexible Electronic Cable: Widely used for Internal Wiring of medical equipment, such as nuclear magnetic resonance instruments and surgical robots. These equipment have precise internal structures and narrow spaces, and require cables to have good flexibility to adapt to the slight movement of the equipment. At the same time, the insulation performance and safety of the cables are extremely high. This cable can meet these conditions, ensuring the normal operation of medical equipment and the safety of patients.

2×16mm² Cable: Can be used for small mobile equipment, such as power supply lines of electric forklifts and stackers. It can bend with the movement of the equipment and is not easy to break.

2×25mm² Cable: Suitable for port lifting equipment, mining mobile machinery, etc. It can maintain stable performance in harsh environments and provide reliable power support for the equipment.

4-Core Flexible Electronic Cable: In the field of automobile manufacturing, it is used for connection of electronic equipment inside automobiles, such as the lines between instrument panels and various sensors, and can adapt to vibration and temperature changes during automobile driving.

Appearance: The cable is round in overall shape with a smooth surface. The sheath has various colors, commonly black and gray, which can be customized according to different use scenarios and customer needs. The surface of the sheath is printed with clear marks, including the cable's specification model, rated voltage, certification marks (such as CCC, UL), manufacturer, etc., which is convenient for users to identify and use.

Structure: 2×16mm² and 2×25mm² cables have a double-core structure, with two conductors arranged in parallel or stranded together, and the outer layer is wrapped with an insulation layer and a sheath; the 4 conductors of the 4-core flexible electronic cable are symmetrically distributed, stranded together and then wrapped with an insulation layer and a sheath, with a compact structure and small space occupation.

Details: The end of the cable is usually specially treated, and connectors or terminals can be added according to customer needs to facilitate connection with equipment. The surface of the sheath can also be printed with anti-slip lines to enhance the grip and facilitate cable laying and arrangement.

Wire Drawing: High-purity electrolytic copper rods are drawn through a wire drawing machine in multiple passes to make fine copper wires with a diameter of 0.1mm-0.25mm. A special lubricant is used during the drawing process to reduce friction between the copper wire and the mold, ensure the surface of the copper wire is smooth, and avoid scratches and cracks.

Bunch Stranding: A certain number of fine copper wires are initially stranded on a bunch stranding machine to form a bunch. During bunch stranding, the stranding tension and pitch are controlled to make the copper wires fit closely together, and at the same time ensure the roundness of the bunch.

Compound Stranding: For conductors with a larger cross-sectional area, such as the conductor of 2×25mm² cable, compound stranding is required. Multiple bunches are stranded again on a compound stranding machine according to a certain stranding direction and pitch to form the final conductor. The compound stranding process can further improve the flexibility and mechanical strength of the conductor and reduce stress concentration during bending.

Material Preparation: PVC Insulation Materials are stirred and dried to remove moisture and impurities in the materials, ensuring the quality of the insulation materials. The dried insulation materials are put into the hopper of the extruder for standby.

Extrusion Molding: A tube-type mold is used for insulation layer extrusion. The Stranded Conductor is passed through the 机头 of the extruder, and at the same time, the molten PVC insulation material is evenly extruded and wrapped on the surface of the conductor to form an insulation layer. During extrusion, the extrusion temperature (usually 150℃-180℃), extrusion speed and traction speed are controlled to ensure that the insulation layer has uniform thickness, a smooth surface, is closely combined with the conductor, and has no defects such as bubbles and depressions.

Cooling and Solidification: The extruded Insulated Wire core immediately enters a cooling water tank for cooling, and the water temperature is controlled at 20℃-30℃ to quickly solidify and shape the insulation layer, ensuring the dimensional stability and performance of the insulation layer.

For 4-core flexible electronic cables, cabling treatment is required. The 4 insulated wire cores are stranded on a cabling machine according to a certain stranding direction and pitch. During stranding, filling materials (such as polypropylene ropes) can be added as needed to make the cable core round and stable. The cabling pitch is usually 10-15 times the outer diameter of the cable to ensure the flexibility of the cable.

For 2×16mm² and 2×25mm² cables, if a stranded structure is adopted, similar cabling treatment is also required to strand the two insulated wire cores together.

Material Preparation: PVC sheath materials are stirred and dried, similar to the treatment of insulation materials.

Extrusion Molding: The cabled core or double-core insulated wire core is sent to the sheath extruder, and the molten PVC sheath material is extruded and wrapped on the outer layer of the cable core through a mold to form a sheath. The extrusion temperature is controlled at 160℃-190℃ to ensure that the sheath material is fully plasticized and closely combined with the inner layer. The size of the mold is precisely designed according to the outer diameter of the cable to ensure uniform thickness of the sheath.

Cooling and Solidification: The extruded cable enters a cooling water tank for cooling, and the cooling method is the same as that for the insulation layer, so that the sheath is quickly solidified to avoid shrinkage, deformation and other problems.

Printing: During the sheath extrusion process, the specification model, rated voltage, certification marks and other information are printed on the surface of the sheath through a printing machine. The printing is clear, firm and not easy to fall off.

Appearance Inspection: Check whether the sheath surface of the cable is smooth, free of bubbles, scratches, depressions and other defects, whether the printing is clear and complete, and whether the conductor is exposed.

Size Measurement: Use calipers and other tools to measure the outer diameter of the cable, the thickness of the insulation layer, the thickness of the sheath and other size parameters to ensure they meet the specification requirements.

Electrical Performance Test: Including insulation resistance test, voltage withstand test (applying 2000V voltage for 1min without breakdown), etc., to inspect whether the insulation performance of the cable meets the standards.

Mechanical Performance Test: Conduct bending tests (≥10000 reciprocating bends without breaking), tensile tests, etc., on the cable to test the mechanical strength and flexibility of the sheath and conductor.

Other Tests: Ozone resistance test (no cracks for 72h under 200ppm concentration), oil resistance test, etc., are carried out as needed to ensure the service performance of the cable in specific environments.

Cable Reel: Wooden cable reels or plastic cable reels are used. Wooden cable reels are made of high-quality pine wood, which has been dried with a moisture content of ≤15% to avoid deformation during transportation and storage. The diameter of the cable reel is determined according to the length and specification of the cable. Usually, the length of 2×16mm² and 2×25mm² cables per reel is 100m-500m, and the corresponding cable reel diameter is 600mm-1000mm; the length of 4-core flexible electronic cables per reel is 200m-1000m, and the cable reel diameter is 500mm-800mm.

Packaging Film: The outer layer of the cable is wrapped with a 0.05mm-0.1mm thick polyethylene film to prevent moisture and dust, and protect the cable surface from contamination and damage.

Protective Cover: Plastic protective covers are installed on both sides of the cable reel to prevent the cable ends from being collided and squeezed, and to avoid moisture entering the inside of the cable.

The cable is neatly coiled on the cable reel. During coiling, the tension is controlled to make the cable arranged closely and neatly without crossing or overlapping. After coiling, the cable reel is fixed on both sides with strapping to prevent the cable from loosening during transportation.

For short-length cables (such as 10m-50m), carton packaging can be used. The cable is neatly placed in the carton, and buffer materials such as foam are filled in the carton to avoid mutual collision of the cables during transportation.

Product labels are pasted on the cable reel or carton, indicating product name, specification model, length, weight, production batch number, production date, implementation standard, manufacturer and other information.

In addition to the basic product information, warning signs such as "Do Not Stack Heavily", "Keep Dry and Avoid Sunlight", "Handle with Care" are printed on the packaging, reminding operators of precautions in the form of diagrams and text.

For exported products, the packaging marks also need to contain English information to meet the requirements of international transportation and sales.

Road Transportation: Suitable for short and medium-distance transportation. Trucks are used for transportation, and the carriage must be clean, dry and free of sharp objects. When loading, the cable reel is placed upright and fixed in the carriage with steel wire ropes and other fixing devices to prevent shaking and dumping during transportation.

Railway Transportation: For long-distance transportation, railway transportation can be chosen. The cable reel is placed on the flat car of the railway freight car, and good fixing and protective measures are taken to ensure transportation safety.

Sea Transportation: Exported products are usually transported by sea. The cable reel is loaded into the container, which should be kept dry and ventilated to prevent the cable from getting damp. The cable reel is fixed with wooden frames in the container to prevent collision during transportation.

During transportation, the cable reel must be kept in an upright state, and it is strictly forbidden to lay it flat or upside down to avoid damage to the cable due to extrusion.

Avoid severe collision and vibration of the cable reel to prevent damage to the outer sheath and insulation layer of the cable.

During transportation, moisture-proof, sun-proof and rain-proof measures should be taken. A rain cloth can be covered on the cable reel to prevent the cable from getting damp and direct sunlight.

When loading and unloading the cable, special hoisting equipment is used. The hoisting point should be located at the center of both sides of the cable reel to avoid deformation of the cable reel or damage to the cable caused by single-point hoisting.

After the customer places an order, the sales department confirms the order information, including product specifications, quantity, delivery date, delivery location, etc., and transmits the order information to the production department or warehouse.

The warehouse prepares goods according to the order information. For products in stock, outgoing inspection is carried out to ensure that the product quality meets the requirements; for products that need to be produced, the production department arranges the production plan, completes the production on time and conducts inspection.

After the product passes the inspection, it is packaged according to the packaging requirements, and transport vehicles are arranged.

Before delivery, warehouse personnel and the transport driver check the product information and quantity together, sign the goods delivery note, and the driver confirms receipt.

The sales department informs the customer of the delivery information, including the transport vehicle number, estimated arrival time, etc., so that the customer can arrange for receipt.

For products in stock, delivery can be arranged within 1-3 working days after the order is confirmed.

For products that need to be produced, the delivery time depends on the production cycle, usually 7-15 working days, which may be extended appropriately for large quantities or special specifications.

The actual delivery time is also affected by factors such as transportation distance and weather conditions. The sales department will communicate with the customer in a timely manner if there is any delay.

Customers can apply for samples to test the performance and quality of the product. The sample specifications are usually the common specifications of the product, such as 2×16mm², 2×25mm² and 4-core (2×0.75mm² + 2×0.5mm²) flexible electronic cables.

The length of each sample is usually 1m-5m, which is sufficient for customers to carry out relevant tests and evaluations.

Samples can be provided free of charge, but the customer needs to bear the freight. For large quantities of samples or special specifications, a certain sample fee may be charged, which can be refunded after the customer places a formal order.

After receiving the customer's sample application, the warehouse will prepare the samples and arrange delivery within 1-2 working days.

Samples are usually delivered by express, which is fast and convenient, and the customer can receive them in a short time.

The sample delivery information, such as the express waybill number, is fed back to the customer in a timely manner, so that the customer can track the logistics information.

The product provides a quality guarantee period of 12-24 months from the date of delivery. During the guarantee period, if the product has quality problems due to manufacturing defects, the manufacturer will provide free replacement or repair services.

The quality guarantee does not cover damage caused by improper use, transportation, storage or man-made damage.

The manufacturer provides technical support to customers, including answering questions about product selection, installation, use and maintenance.

Technical personnel can be dispatched to the customer's site to provide guidance and assistance if necessary, such as on-site installation guidance and problem diagnosis.

If the customer has any complaints about the product or service, they can contact the after-sales service department through phone, email, etc.

The after-sales service department will respond to the customer's complaint within 24 hours, conduct an investigation and analysis, and give a solution within 3-5 working days.

For reasonable complaints, the manufacturer will actively handle them to ensure the customer's satisfaction.

If the product has quality problems that cannot be repaired, or if the delivered product does not conform to the order requirements (such as wrong specifications, wrong models), the customer can apply for return or exchange.

The return or exchange process needs to be handled within 30 days from the date of receipt of the goods. The customer shall provide relevant proofs, such as photos of the product, test reports, etc.

The manufacturer shall bear the freight for return and exchange caused by product quality problems or delivery errors; for return and exchange caused by the customer's own reasons, the customer shall bear the freight.