Method for preventing oxidation of general purpose rubber sheathed cable conductors
2017-04-25
General rubber cable is 5 types of copper conductor as the conductive core, in its production process, often found that the copper conductor oxidation discoloration, which seriously affected the quality of the product, has become a domestic many cable manufacturers a long-term technical problems.
Copper is a transition metal and is easily oxidized by oxygen in the air under acidic conditions to black CuO. When there is a water film or water droplets on the surface of the copper conductor, because the atmosphere contains a lot of dust, such as smoke, coal, automobile exhaust, chloride and other acid, alkali, salt particle dust, etc., these harmful substances are dissolved in the water film or water droplets, The electrolyte can be formed, which aggravates the oxidation discoloration of the copper conductor. The light ones affect the appearance quality and product quality of the products, while the heavy ones affect the use of copper conductors, resulting in waste of production costs. Therefore, the copper conductor must be properly kept, pay attention to anti-oxidation discoloration.
In principle, there are mainly physical methods to block copper from contacting humid air, cathodic protection redox method to prevent oxidation of copper conductors, chemical methods to generate passivation film on the surface of copper conductors to prevent oxidation, or spraying special liquid on the surface of conductors to protect them. Taking the production of general-purpose rubber-sheathed cable as an example, the main method of anti-oxidation control in each process.
1. Transportation, testing and storage of copper rod before entering the factory
Most of China's cable enterprises with copper for outsourcing, should choose high-quality metal copper rod, standardize the supplier transportation, delivery process and system, copper rod into the factory inspection in accordance with GB/T 3048.2 or cable enterprise standard implementation. The copper rod can be stored with plastic cloth or plastic film covering the copper rod, that is, the simplest physical barrier method prevents the copper rod from contacting with humid air. When collecting copper rods in the workshop, it is necessary to check the copper rod rolls one by one for visual inspection for blackening and control them from the source of production.
2. Control of copper rod drawing process
The drawing of 0.4mm monofilament generally adopts continuous annealing copper large drawing machine and medium drawing machine, which need to go through the processes of setting out, drawing and annealing, cooling, drying, and taking-up. First of all, you should select the appropriate mold, must not be too small, otherwise it will force the metal copper lattice variation, exacerbate the sharp rise in metal temperature. Secondly, check the pH value of the emulsion before starting the machine to ensure that it is alkaline solution. At the same time, antioxidant should be added to the drawing oil to form a passivation film on the surface of the copper conductor to prevent oxidation. When setting out, keep the setting-out tension stable and uniform without excessive vibration. During wire drawing, the operator should ensure the appropriate water level height, ensure uniform annealing degree, and avoid insufficient annealing or excessive annealing. During wire take-up, there should be no residual liquid on the copper conductor surface, A piece of dry felt (often replaced) can be placed in front of the take-up to ensure the drying of the monofilament. Finally, after drawing the lower plate, it is sealed with a transparent plastic film and stored in a dry environment to be circulated, otherwise it will be easy to oxidize with humid air due to the high surface temperature of the conductor.
3. Copper wire stranding (bundling), insulating rubber and sheath rubber extrusion process
Taking copper wire stranding as an example, during the stranding process of the conductor, the metal copper lattice changes its structure through each die. Under the action of strong external force, the temperature of the copper conductor after overmolding is greatly increased compared with that before overmolding, so the outer layer of the copper conductor is easy to oxidize. Therefore, antioxidant (0.3% benzotriazole alcohol solution) can be dripped into the copper wire with an infusion hose during twisting. The dripping standard is based on just infiltrating the surface of the copper wire, so as to avoid the occurrence of too little local oxidation or too much waste. After all the anti-oxidation work is prepared and stable, the machine is started again. The take-up place shall be dry and sealed with transparent plastic film after the take-up reel is full.
Conductor shall be longitudinally wrapped or wrapped with polyester tape before extrusion insulation, and the substances in rubber insulation material shall be placed to corrode the conductor. Insulation rubber and sheath rubber in the extrusion process, should avoid the thread head water, and the thread head oxidation black phenomenon.
In our daily production observation, we found that by selecting high-quality copper rods, effectively controlling the wire drawing process and the concentration and temperature of emulsion, annealing process, passivation treatment on the surface of conductor stranding or bundling copper wire, and preventing water from entering the wire end, in addition, workshop operators should establish quality awareness and strengthen business training, so as to clearly recognize the adverse consequences brought by copper wire oxidation and strictly control the quality, in order to effectively control the quality of the cable copper conductor, prevent its oxidation, greatly improve the work efficiency, reduce the frequency of rework, so as to achieve the beneficial effect of reducing costs and improving the quality of the internal products.
Prevention, conductor, oxidation, cable, surface, copper wire, drawing, annealing, take-up wire, metal
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