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Common Quality Issues and Solutions in the Cable Production Process
Created on 2025.11.14
I. Quality Problems and Solutions in the Extrusion Process
1. Appearance Defects
During the cable extrusion process, appearance defects may occur, such as burrs, bubbles, black spots, etc. Among them, burrs are caused by unreasonable or incorrect design of the extrusion head, which leads to poor melt flow distribution; bubbles may result from unevaporated moisture or undispersed air bubbles in the melt, or unstable air pressure during extrusion; black spots may be due to foreign matter mixed in the melt or contamination during the extrusion process.
Solutions:
- Check whether the design of the extrusion head is reasonable and adjust its structure appropriately.
- Reduce the moisture content in the melt or use a pressure pump.
- Clean the equipment regularly and replace the filter elements.
2. Dimensional Deviation
Dimensional deviation is a common quality problem in the extrusion process. It may be caused by improper design of the extrusion head or mold, or unstable temperature control during extrusion. Excessive dimensional deviation of the cable will lead to a decline in its electrical performance.
Solutions:
- Design a reasonable extrusion head and mold in accordance with the requirements of the extrusion process.
- Implement strict management of the temperature control equipment during extrusion to ensure temperature stability and accuracy.
II. Quality Problems and Solutions in the Insulation Layer Production Process
1. Uneven Distribution of Defects
A common problem in insulation layer production is the uneven distribution of defects in the insulation layer, especially uneven distribution in the thickness direction. This will also cause a decrease in the electrical performance of the cable.
Solutions:
- Optimize the production process, strengthen process control, and conduct production in strict accordance with production requirements.
- Maintain and clean the production equipment, and make adjustments based on actual conditions.
2. Thickness Deviation of the Insulation Layer
The thickness of the insulation layer is also a quality concern. Generally, an excessively thin insulation layer may lead to a decrease in breakdown voltage, while an excessively thick one will increase product loss and production costs.
Solutions:
- Replace with a suitable mold, adjust the structure of the extrusion head and equipment parameters.
- Strictly control parameters such as temperature and speed during the production process.
III. Quality Problems and Solutions in the Sheathing Process
1. Unstable Joints
Problems with cable joint quality may lead to a decline in the overall performance of the cable. Unstable joints are a common quality issue in the sheathing process, which may be caused by poor quality of joint materials or non-standard operations during production.
Solutions:
- Improve the production process level of joints, select high-quality joint materials.
- Strengthen training and management on standard operating procedures.
2. Failure of Steel Tape Cladding
Steel tape cladding plays an important protective role in cable production. However, the failure of steel tape cladding will cause a series of problems for the cable, such as thermal aging of the cable and erosion by the external environment.
Solutions:
- Select high-quality steel tape materials to ensure good performance of steel tape cladding.
- Inspect the insulation layer of the cable before steel tape cladding to ensure its quality.
Conclusion
There are many quality problems in cable production, and potential quality issues may exist in each process. By strictly controlling the production process, strengthening the management of equipment and materials, and continuously optimizing the production process, the occurrence rate of quality problems can be effectively reduced, and the quality and performance of cable products can be improved.