I. Product-specific Information
(1) Specifications and Parameters
VSD/EMC screened cables,
Frequency Converter Cables and 3c+3e cables have rigorous settings in terms of specifications and parameters to adapt to power transmission needs in complex electromagnetic environments.
In terms of conductor specifications, the conductors of such cables mostly use high-purity copper, with a wide range of cross-sectional areas, commonly 1.5mm², 2.5mm², 4mm², 6mm², 10mm², etc. The current-carrying capacity of conductors with different cross-sectional areas varies significantly. At an ambient temperature of 25℃, the current-carrying capacity of 1.5mm² is about 20A, 2.5mm² is about 28A, 4mm² is about 38A, 6mm² is about 48A, and 10mm² is about 65A, which can be selected according to the power requirements of different equipment.
Shielding performance parameters are one of its core characteristics. In the multi-layer shielding structure, the thickness of the copper tape wrapped shielding is usually 0.1mm-0.3mm, and the overlap rate is not less than 15%; the diameter of the
Copper Wire for the copper wire braided shielding is about 0.15mm-0.3mm, and the braiding density is not less than 85%, which makes the shielding effectiveness of the cable reach more than 80dB, effectively blocking the incoming and outgoing of electromagnetic interference and radio frequency interference.
In terms of electrical performance, the rated voltage of the cable is mostly 0.6/1kV, which meets the voltage requirements of the frequency conversion system. The insulation resistance is not less than 1000MΩ·km at 20℃, and the dielectric loss tangent value is not more than 0.003, ensuring good electrical insulation performance. In addition, the capacitance and inductance values of the cable are precisely controlled, which can reduce signal attenuation and reflection during high-frequency transmission, ensuring the integrity of signal transmission.
The mechanical performance parameters are also excellent. The tensile strength of the cable is not less than 12MPa, and the elongation at break is not less than 150%, which can withstand a certain degree of external tension without being easily damaged. In terms of bending performance, the static bending radius is not less than 12 times the outer diameter of the cable, and the dynamic bending radius is not less than 20 times the outer diameter of the cable, which is convenient for laying in the complex space inside the equipment.
(2) Characteristic Applications
VSD/EMC screened cables, frequency converter cables and 3c+3e cables have characteristic applications in many fields due to their unique performance.
In industrial automation production lines, various motors, conveyors and other equipment are controlled by frequency conversion systems, which have high requirements for the anti-interference ability of cables. Such cables can effectively resist electromagnetic interference generated by many equipment in the production line, ensure the stable transmission of frequency conversion signals, make the equipment operate accurately according to the preset program, and improve production efficiency and product quality. For example, in automobile manufacturing production lines, the frequency conversion control lines of welding robots, assembly lines and other equipment use such cables in large quantities.
The elevator drive system is an important application scenario. During the operation of the elevator, the frequency converter starts and stops frequently, which will generate strong electromagnetic interference. At the same time, the environment in the elevator shaft is complex, with various signal interferences. The use of such cables can ensure that the power transmission and signal control of the elevator drive system are not disturbed, ensure the smooth operation and accurate docking of the elevator, and ensure the safety of passengers.
Machine tool frequency conversion equipment has strict requirements on cable performance. When the machine tool is running at high speed and performing precision machining, it needs stable power supply and accurate signal control. Such cables can adapt to the high-frequency working state of machine tool frequency conversion equipment, resist electromagnetic interference generated by equipment operation, ensure the machining accuracy and working efficiency of the machine tool, and are widely used in CNC machine tools, machining centers and other equipment.
In addition, such cables also play an important role in fields such as wind power generation and rail transit. The frequency conversion control system of wind turbines needs to operate stably in a strong electromagnetic environment, and such cables can meet its needs; the power transmission and signal control of traction converters, auxiliary converters and other equipment in rail transit also rely on the anti-interference performance of such cables.
(3) Material and Style
Material
Conductor: High-purity oxygen-free copper is used, with a purity of more than 99.95%. Oxygen-free copper has excellent conductivity, with a conductivity of 100% IACS, which can reduce losses during power transmission and ensure efficient transmission of current. At the same time, oxygen-free copper has good Flexibility, is easy to be processed into conductors of various specifications, and has good corrosion resistance, which can maintain stable performance in long-term use.
Insulation layer: Mainly uses cross-linked polyethylene (XLPE) or polyvinyl chloride (PVC). After cross-linking treatment, the XLPE insulation layer forms a three-dimensional network structure, which has excellent heat resistance. The long-term working temperature can reach 90℃, and the short-term overload temperature can be as high as 130℃, which can adapt to the temperature change when the frequency converter starts and stops frequently. At the same time, XLPE also has good chemical corrosion resistance and aging resistance, and has a long service life. PVC Insulation layer has relatively low cost, certain heat resistance and insulation performance, and is suitable for scenarios with relatively low performance requirements.
Sheath: Mostly uses polyvinyl chloride (PVC) or polyurethane (PU) materials. PVC Sheath has good mechanical strength and weather resistance, which can protect the internal structure of the cable from external mechanical damage and environmental erosion; PU sheath has better wear resistance and flexibility, and is suitable for occasions that require frequent movement or bending.
Style
There are various styles of such cables. Among them, the 3c+3e cable has a typical
Multi-Core structure. The 3 main core wires of "3c" are usually yellow, green and red, used for three-phase power transmission; the 3 wires of "3e" are mostly blue, black and yellow-green 双色，which are used as neutral wire, signal wire and
Grounding Wire respectively. The overall appearance is round, and the outer diameter of cables with different specifications is different. The outer diameter of 1.5mm² is about 10mm, 2.5mm² is about 12mm, 4mm² is about 14mm, 6mm² is about 16mm, and 10mm² is about 18mm.
The surface of the cable sheath is smooth and flat, and some styles will be printed with specifications, models, manufacturers and other marks for easy identification. In addition, according to different use scenarios, there are also
Armored Cables. The armor layer is made of
Steel Tape or steel wire, which can enhance the cable's resistance to mechanical damage and is suitable for harsh environments such as buried laying.
(4) Production Process
The production process of VSD/EMC screened cables, frequency converter cables and 3c+3e cables is advanced and complex, ensuring that the products have excellent performance.
First, in the manufacture of conductors, high-purity oxygen-free copper rods are drawn into copper wires of the required diameter through a wire drawing machine, and then annealed to eliminate internal stress in the copper wires and improve their flexibility. After that, according to the requirements of different cross-sectional areas, multiple copper wires are stranded to form a conductor. During the stranding process, the stranding pitch is strictly controlled to ensure the roundness and stability of the conductor.
Next is the extrusion of the insulation layer. For cables using XLPE insulation, XLPE particles are added to the extruder, heated to a molten state (temperature about 120℃-180℃), and uniformly extruded and coated on the surface of the conductor through a mold to form an insulation layer. After extrusion, the insulation layer is cross-linked, usually by dry cross-linking, so that the XLPE molecules form a three-dimensional network structure to improve the insulation performance. For cables with PVC insulation, PVC particles are heated and melted and then extruded and coated on the surface of the conductor, with an extrusion temperature of about 150℃-170℃.
Then comes the production of the shielding layer. First, wrap copper tape around the outside of the insulation layer to ensure that the copper tape is closely attached to the insulation layer and the overlap rate meets the requirements. After that, braid copper wires on the outside of the copper tape, control the braiding density and tension to form a multi-layer shielding structure. After the shielding layer is made, a layer of wrapping tape is wrapped around its outside to enhance the integrity and stability of the shielding layer.
For 3c+3e cables, a cabling process is also required. The 3 main core wires and 3 auxiliary wires are stranded together according to certain stranding rules, and appropriate filling materials are filled between the core wires to make the cable round. After cabling, the sheath is extruded. The sheath material is selected as PVC or PU according to the style. During the extrusion process, the temperature, speed and pressure are controlled to ensure that the sheath has a uniform thickness, a smooth surface and is closely combined with the internal structure.
During the production process, each process is equipped with strict quality inspection, including the detection of conductor diameter, insulation layer thickness, shielding layer performance, sheath performance, etc., to ensure that the products meet relevant standards.
II. General Product Information
(1) Packaging
To ensure the quality of VSD/EMC screened cables, frequency converter cables and 3c+3e cables during transportation and storage, a professional packaging method is adopted.
For long-length cables, they are usually wound on steel cable reels. The diameter of the cable reel depends on the cable specification and length. Small-sized cables can use cable reels with a diameter of 800mm-1000mm, while large-sized cables use 1200mm-1600mm cable reels. Both sides of the cable reel are equipped with solid baffles with a thickness of not less than 20mm, which can effectively prevent the cable from slipping. The center of the cable reel is provided with a shaft hole for easy hoisting and handling.
After the cable is wound on the cable reel, it will be tightly wrapped with plastic film to prevent contamination by dust, moisture and oil. For each reel of cable, clear product information will be marked on the side of the cable reel, including product name, specification model, length, weight, production date, implementation standard, manufacturer, etc., which is convenient for customers to identify and count. The packaging is also printed with warning signs such as "Do not invert", "Handle with care", "Moisture-proof and sun-proof" to remind relevant personnel to pay attention to protection.
For short-length cables, they can be packaged in rolls, wrapped with plastic film and then put into cartons. The cartons have high strength and can prevent the cables from being damaged by extrusion.
(2) Transportation
Transportation methods: According to the transportation distance and order quantity, different transportation methods can be selected. For short-distance transportation, road transportation is generally used, and trucks are used to load cable reels. The trucks need to be equipped with fixing devices to firmly fix the cable reels to prevent shaking during transportation. For long-distance transportation, railway transportation can be selected, which has good stability and is suitable for transporting large quantities of cables; for areas with ports, waterway transportation can also be used, with relatively low cost.
Transportation precautions: During transportation, the cable reel must be placed horizontally, and it is strictly forbidden to tilt or invert to avoid the cable slipping off the cable reel. A certain distance should be kept between cable reels to prevent mutual collision and extrusion, which may cause damage to the cable outer sheath and internal structure. Transport vehicles or means of transport should take rain-proof, sun-proof and dust-proof measures, such as covering with rain-proof cloth, to avoid the cable being affected by bad weather. When loading and unloading the cable reel, special hoisting equipment must be used, and the hoisting point should be selected at the lifting ring of the cable reel. Hoisting at the baffle or other parts is not allowed to avoid damaging the cable reel and the cable. During transportation, traffic rules must be observed, driving should be smooth, and operations such as sudden braking and sharp turns should be avoided to reduce the impact on the cable.
(3) Delivery
Delivery time: After the customer confirms the order and makes payment, we will arrange delivery as soon as possible. For specifications in stock, they can usually be shipped within 3-5 working days; for customized specifications or large quantities of orders, the production cycle will be extended according to the actual situation. We will communicate with the customer in advance to clarify the delivery time to ensure that the customer can reasonably arrange subsequent work.
Delivery process: First, warehouse personnel accurately pick cables of corresponding specifications and lengths according to the order information and conduct strict checks to ensure that the product information is consistent with the order. Then, re-inspect the cable, confirm that there is no quality problem, and package it according to the packaging standards. After that, contact the cooperative logistics company, arrange transport vehicles, safely load the cable onto the vehicle and fix it firmly. After delivery, we will promptly inform the customer of logistics information (such as logistics company name, waybill number, contact information, etc.) via SMS, email, etc., to facilitate the customer to track the transportation status of the goods. At the same time, we will maintain close communication with the logistics company to keep abreast of the transportation of the goods and ensure that the goods are delivered on time and safely.
(4) Samples
To allow customers to fully understand the product quality and performance before mass purchase, we provide sample services.
Customers can apply for samples from us, stating the specification model, length and other information of the required cable. We will prepare the samples within 1-3 working days after receiving the application. The length of the samples is generally 1-2 meters, which can meet the customer's testing needs for the appearance, structure, performance, etc. of the cable.
The quality of the samples is consistent with that of mass-produced products, and strictly follows the same production process and quality standards. In terms of sample fees, for ordinary customers, we will charge a certain sample fee and freight, and the sample fee can be deducted when the customer makes subsequent mass purchases; for long-term cooperative old customers or large customers with clear intention of mass purchase, we can provide free samples, and the freight is borne by the customer or negotiated by both parties.
After the sample is sent, we will promptly inform the customer of the express information of the sample. After the customer receives the sample, if there are any questions, our technical personnel will provide professional answers and technical support.
(5) After-sales Service
We have a complete after-sales service system to provide customers with comprehensive after-sales guarantee.
Quality assurance: This series of cable products provides a 15-year warranty period. During the warranty period, if the cable cannot be used normally due to its own quality problems (such as conductor breakage, insulation layer damage, shielding layer failure, etc.), we will provide customers with free repair or replacement services. If the damage is caused by non-product quality reasons such as improper installation and wrong use by the customer, we can also provide repair services, but will charge corresponding repair fees and material fees.
Technical support: Customers can contact our technical personnel at any time if they encounter any technical problems during the installation, laying, use and maintenance of the cable. Our technical personnel will provide customers with professional technical guidance through telephone, email, video, etc., such as installation methods, laying precautions, fault diagnosis, etc. When necessary, we can dispatch technical personnel to provide on-site technical support.
Complaint handling: If customers are dissatisfied with products or services, they can complain through customer service hotlines, emails and other channels. We will respond to the complaint within 24 hours, arrange a dedicated person to handle it, and give a satisfactory solution within 7 working days to ensure that the reasonable demands of customers are met.
Regular return visits: We will conduct regular return visits to customers who have purchased the products to understand the use of the cables, collect customers' opinions and suggestions, and continuously improve product and service quality to enhance customer satisfaction.
In conclusion, VSD/EMC screened cables, frequency converter cables and 3c+3e cables, with their excellent specifications and parameters, extensive characteristic applications, high-quality materials and styles, advanced production processes, as well as perfect packaging, transportation, delivery, sample and after-sales services, have become ideal choices for power transmission in complex electromagnetic environments, and can provide reliable line support for various industrial equipment and systems.
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