Cable Manufacturing Research Articles

Design of Underwater Cables Applicable to Submarine(KSS-III Batch-II) Navigation Radar

Since the creation of the first submarine telegraph cable connecting England and France in 1850, today, due to the rapid development of the Internet and Communications fields, the demand for submarine communication cables has increased and continues to develop. Submarine cables are designed and manufactured to be suitable for the maritime environment, and many parts are imported from overseas, and several domestic cable manufacturers are producing them for commercial purposes. Field-proven and reliable commercial submarine communication cable technology is also being applied to the military field, and is especially actively utilized in naval surface ships and submarines. This paper is about the design of an underwater cable applicable to submarine(KSS-III Bach-II) navigation radar and also is to secure the performance of an underwater cable with bending durability in extreme marine environments, emergency diving, and repeated mast raising and lowering. Finally, we hop that the domestic development of underwater cables will help improve the performance of navigation radars for submarines.

A Novel IMU-Based System for Work-Related Musculoskeletal Disorders Risk Assessment.

This study introduces a novel wearable Inertial Measurement Unit (IMU)-based system for an objective and comprehensive assessment of Work-Related Musculoskeletal Disorders (WMSDs), thus enhancing workplace safety. The system integrates wearable technology with a user-friendly interface, providing magnetometer-free orientation estimation, joint angle measurements, and WMSDs risk evaluation. Tested in a cable manufacturing facility, the system was evaluated with ten female employees. The evaluation involved work cycle identification, inter-subject comparisons, and benchmarking against standard WMSD risk assessments like RULA, REBA, Strain Index, and Rodgers Muscle Fatigue Analysis. The evaluation demonstrated uniform joint patterns across participants (ICC=0.72±0.23) and revealed a higher occurrence of postures warranting further investigation, which is not easily detected by traditional methods such as RULA. The experimental results showed that the proposed system's risk assessments closely aligned with the established methods and enabled detailed and targeted risk assessments, pinpointing specific bodily areas for immediate ergonomic interventions. This approach not only enhances the detection of ergonomic risks but also supports the development of personalized intervention strategies, addressing common workplace issues such as tendinitis, low back pain, and carpal tunnel syndrome. The outcomes highlight the system's sensitivity and specificity in identifying ergonomic hazards. Future efforts should focus on broader validation and exploring the relative influence of various WMSDs risk factors to refine risk assessment and intervention strategies for improved applicability in occupational health.

Improved genetic algorithm based on rule optimization strategy for fibre allocation

ABSTRACT In modern manufacturing industry, in order to adapt to changes in the general environment, the manufacturing industry must improve production efficiency. To this end, this article introduces an improved genetic algorithm based on rule selection to tackle the nondeterministic polynomial hard problem stemming from inventory fibre resources and fibre selection principles in optical cable production. The algorithm aims to maximize inventory score and minimize fibre segmentation rate. It employs a permutation encoding approach to link the genetic algorithm with fibre allocation solutions and applies a self-attention mechanism to determine subset solution weight within each solution. To boost the recombination of favourable gene segments from different chromosomes, a rule optimization strategy is integrated into the crossover operation based on the weights. This operations enhance the algorithm's global search capability and convergence speed. A feasibility repair strategy is then used to inspect and rectify chromosomes, preventing the generation of illegal solutions. The legitimate mutation operation, founded on weight optimization rules, effectively reduces the algorithm's running time by avoiding illegal solutions. By leveraging actual production data from an optical cable manufacturer for simulation, the experimental results confirm the effectiveness of the improved genetic algorithm in addressing the fibre allocation problem. Comparative simulations with the unimproved genetic algorithm and a stepwise greedy algorithm underscore the superiority of the improved genetic algorithm in resolving the fibre allocation problem.

Manufacture and Testing of Pre-prototype HTS Twisted Stack Slotted-Core Cable

Manufacture and Testing of Pre-prototype HTS Twisted Stack Slotted-Core Cable

Productivity improvement of control cable manufacturing machine for the automotive industry

Due to the high competitiveness that characterizes the automotive industry (AI), there is an intensive search for improvements that translates into significant impacts on the productivity, still guaranteeing the levels of quality required by the client. The requirement for flexibility is leading to a paradigm shift that arises from a constant change in the needs of consumers, who demand an ever-higher level of customization in the products. In recent years, the increasing use of automation in industry resulted in significantly improved product quality, better working environment, higher cost efficiency, and major improvement in process flexibility. The present work addresses the productivity improvement of a control cable manufacturing machine for the AI. The main objective is related to the development of a new stripping machine concept that allows the simultaneous coating removal from two cables, thus eliminating an existing bottleneck in the injection process of the cables’ first Zamak terminal. A prototype machine was built, and the new concept validated, and then implemented in the factory. An automatic cable extraction system was also designed, aiming to reduce the number of manual tasks performed by the operator, with the expectation of further improving the process productivity. The development of the two new mechanisms followed the Design Science Research (DSR) methodology. With the implementation of the new double stripping concept and automatic cable extraction system, a major increase in productivity (up to 87.8% compared to the current condition) and cost reduction were achieved.

Enhanced Electrical Conductivity of Graphene-Incorporated Copper Wire and its Performances on Coaxial Cable Application at Sub 6 GHz

Intensive global research is focused on advanced conductive materials to meet the electrical requirements of the telecommunication and power industry. The primary aim is to enhance electrical conductivity, resulting of improved current-carrying capacity and reduced energy loss during transmission. Copper and its composites are vital for power transmission and telecommunications due to their electrical, thermal, and mechanical qualities. However, current methods have drawbacks, such as compromised conductivity with alloying. Graphene, an extraordinary carbon allotrope with exceptional properties and high conductivity, offers promising opportunities for the development of superior materials; such as graphene-incorporated copper (GrCu). The incorporation of graphene into copper wire holds significant potential for various industries, including electronics, energy transmission, and telecommunications, where high conductivity and reliability are paramount. This study investigates GrCu characteristics through mixing graphene and copper, vacuum melting, fine copper wire drawing, and GrCu coaxial cable manufacturing. Graphene infusion enhances conductivity and mechanical properties, altering microstructure and inducing twin boundaries in copper grains. Graphene's disruption during wire drawing triggers this effect, elevating wire conductivity to 103.5% by IACS. GrCu coaxial cable demonstrates performance coherence with HFSS simulation up to 6 GHz. Graphene's inclusion offers tailored material properties. Ongoing research promises further optimization and advancement of graphene-copper composites, paving the way for novel technological progress.

Industrial clusters as a vehicle for circular economy transition: A case study of networks in four industrial clusters in Zimbabwe

Multiple stakeholder partnerships are required to attain a Circular Economy (CE). Circularity can be achieved through industrial clusters in geographical proximity to each other. This research aims to assess the effects of industrial clustering on the adoption of CE in Zimbabwe (Workington, Southerton, Willowvale and Stapleford) in order to develop strategies for strengthening the impact of collaboration on CE practices in industry. The Workington and Southerton clusters were assessed as a joint cluster due to regular joint programming, whereas Willowvale and Stapleford were assessed separately. Interviews, document reviews and site visits were undertaken at selected members within the industrial clusters to understand some CE initiatives being carried out. A waste auditing programme was evaluated, resulting in ecological and economic benefits. Whilst many organisations were located in clusters, not all of them participated in CE activities. The Workington-Southerton cluster consisted of twenty-five (25) active members mainly dominated by private sector organisations in the manufacturing sector whilst Willowvale cluster had four (4) active members and Stapleford had nine (9) active members from industry and community network at the time of assessment. The main types of industries included food and beverages, fertiliser, metal fabrication, cable manufacturing, seed processing. Engineering, transport and bone char production. Collaboration based on geographical proximity allowed the organisations to undertake training, capacity building, workshops and industrial symbiosis. Implementation of the Industrial Waste Auditing Project (IWAP) by the networks, facilitated adoption of CE measures and presented an opportunity of improved waste recycling. It is concluded that geographical proximity can be used as an opportunity to facilitate attainment of a Circular Economy, but on its own is not a determinant of network success. Deeper issues of legal status, governance, value adding activities and financial viability - determine the ultimate impact of industrial clusters. We conclude that due to geographical proximity, there are opportunities of promoting industrial symbiosis. However, these opportunities need financing, technical capacity, governance and external support. Theoretical contributions of the research relate to the need for hybrid financing models to support CE activities and governance frameworks that provide oversight on industrial clusters. Further theoretical contributions relate to the new forms association beyond idiosyncratic organisations and advancing the need for measurable effects of collaboration using hybrid financing. Our theoretical contributions reveal new insights in governance and ownership of networks, especially how this can affect the delivery of CE activities.

Wire and Cable Quality Traceability System Based on Industrial Internet of Things and Blockchain

Wire and cable are important industrial products involving the national economy and people’s livelihood, which are hailed as the “blood vessel” and “nerve” of the national economy, providing the basic guarantee for the normal operation of modern economy and society. The data traceability of their production and circulation process is a key factor in ensuring their quality and safety management. We aim to solve the problems of unsafe data transmission, weak quality control, and information islands in the process of wire and cable quality traceability in order to improve the production management efficiency of wire and cable manufacturing enterprises and to reduce the cost of consumer quality traceability of wire and cable products. We analyzed the technical characteristics and advantages of Industrial Internet of Things (IIoT) identity resolution and the blockchain. Key technologies are introduced, a traceability method that integrates the two is proposed, and a quality traceability framework based on the IIoT identity resolution system and blockchain technology is constructed. By analyzing the quality information composition of the wire and cable supply chain, a new quality traceability model based on the wire and cable supply chain is established. Finally, through the verification of the developed quality traceability system, the quality traceability function and quality information of each production link of wire and cable are successfully realized. This paper fills a gap in the field of cable product quality traceability using the combination of IIoT and blockchain technology. According to this model, it also has some potential for the traceability of other industrial products.

Novel SolidStir extrusion technology for enhanced conductivity cable manufacturing via in-situ exfoliation of graphite to graphene

Electrification is a path towards decarbonization. Identification of novel nanocarbon materials such as graphene or carbon nanotubes (CNTs) offers great potential as a reinforcement material in metal matrix composites (MMCs) due to their superior strength and electrical properties. However, challenges exist in achieving uniform dispersion of graphene during manufacturing. Traditional methods and advanced techniques like chemical vapor deposition or spark plasma sintering have limitations in terms of cost and scale of production. In this research, a friction-stir based novel SolidStir® Extrusion (SSE) technique was used for the in situ synthesis of Al-graphene MMC cables. Key factors and phenomena driving the exfoliation process that leads to graphite → graphene conversion during SSE were studied by comprehensive characterization techniques such as Raman spectroscopy and transmission electron microscopy. A constitutive Raman analysis revealed that SSE led to the exfoliation of graphite into multilayered graphene. Furthermore, mechanical property characterization and electrical conductivity (EC) tests conducted on SSE-processed Al-graphene MMC cables demonstrated a favorable synergy between strength and EC. The findings of this study provide a benchmark to understand the SSE capabilities to produce next-generation conductive cables for energy and power sectors.

CONTRIBUTIONS REGARDING NON-CONFORMITY MANAGEMENT OF TECHNOLOGICAL PROCESSES IN A WIRE DRAWING FACTORY

In order to demonstrate the way of meeting the quality requirements by electric cable manufacturers, different quality tools can be used to achieve the quality objectives imposed in the Quality Manual such as: SWOT Analysis, PEST Analysis, 8D methodology in handling complaints and methodologies Fishbone and 5Why in dealing with Critical Nonconformances. According to these, the article includes several types of analyzes that are carried out in a wire drawing factory, namely: the Swot analysis, which is a very good way of evaluating the general state of an organization so that a development plan in which to take into account its strong points, to eliminate the weak points, to efficiently exploit the opportunities that have arisen and to allow countering possible threats; Pest analysis that takes into account political factors, economic factors, social factors and technological factors. Within the Quality Management System, the guidelines and responsibilities for the correct management of non-conformities were officially defined by identifying their causes and implementing all the necessary actions for their final solution in all manufacturing processes.

Online defect detection method of optical cable pitch based on machine vision technology and deep learning algorithms

In the field of optical cable manufacturing, the pitch error of finished optical cable exceeding 2 % is considered a defect. Currently, there is no method for online detection of pitch defect in optical cable. Therefore, this paper proposes an online intelligent detection method for cable pitch defects. This method utilizes a multi-sensor fusion image acquisition platform consisting of a Doppler laser velocimeter and an industrial line scan CCD to achieve visual information acquisition of ultra long measured objects. A mathematical model that integrates cascaded dual deep convolutional networks and iterative approximation algorithms based on deep learning technology is proposed for defect detection of optical cable pitch. In order to verify the accuracy and stability of the on-line detection method, 6 types of optical cables were prepared for experimental testing. The experimental results show that the method is robust in the field of engineering detection, and the detection results meet the accuracy requirements.

Understanding Taiwan’s offshore wind industry

Understanding taiwan’s offshore wind industry Here, Open Access Government speaks to Gwo-shyh Song, Chairman of MMA Global Aqua, and explores the challenges, successes and long term plans for the offshore wind power projects in Taiwan. Can you provide an overview of the current state of the offshore wind industry in Taiwan and its significance in the country’s energy transformation? Taiwan had no experience in offshore wind power development in the past. The offshore wind power industry includes wind farm developers, who conduct environmental assessments of wind farms, as well as wind turbine system suppliers, marine engineering companies, cable manufacturers, and wind farm operators. Therefore, the Ministry of Economic Affairs allows 100% foreign ownership to attract foreign investment and gradually increases domestic demand to cultivate local related companies in order to achieve the goal of offshore wind power localization.

Design and control of an automatic cable-cutting machine with the implementation of a stepper control program using PLC

Proper control design will reduce energy losses and production costs for the industry. Control system design also reduces the role of humans in production. An automatic cable-cutting control system can reduce cable manufacturing time so that a company's human resources do not need to carry out the cable-cutting process manually. This cable cutter uses a PLC for its central control, which will convert the length value into the number of pulses and calculate the number of cables to be cut. The HMI inputs the length of the cable to be cut and the number of cables to be missed. The stepper motor is used to run the cable-pulling mechanic, which will pull according to the size stated on the HMI. This system can cut AWG20 and AWG16 cables in various lengths from 50 mm to 3000 mm with the number or number of wires that can be set from 1 cut to 10 cuts for each size.

The enhanced physical properties of XLPE insulation for high voltage cable based on LDPE/LLDPE or LDPE/HDPE blends

Exploring methods of improving the performance of high-voltage cable XLPE insulation is a hot issue in high-voltage and insulation technology. This paper presented a new method to improve the physical properties of XLPE by doping low-content polyolefin materials, such as LLDPE or HDPE. The new XLPE insulation has significantly improved high-temperature mechanical properties and slightly improved room-temperature mechanical properties. The optimal thermal elongation properties were achieved with a 1 phr content of HDPE and LLDPE, while DC conductivity, DC breakdown strength, and dielectric properties were stable or slightly improved. The properties mentioned above showed a decreasing trend at higher content. This study demonstrated that adding HDPE or LLDPE to LDPE increases the physical entanglement of XLPE molecular chains, which has a similar effect to crosslinks formed by chemical crosslinking in enhancing the mechanical properties of XLPE insulation. This suggests that there is a potential to reduce the concentration of crosslinking agents during XLPE cable manufacturing while maintaining electrical properties and improving mechanical properties at elevated temperatures. It provides a new idea for improving the properties of XLPE insulation for high-voltage DC cables.

Insulation aging diagnosis and defect location of crosslinked polyethylene cable in the distribution network based on radio frequency identification

With the expansion of power grid construction, the regulatory requirements of various equipment are increasing. Further, the safe and stable operation of the distribution network plays a crucial role in the entire power system. In particular, the cables in DNs are prone to aging during long-term operation due to various factors, such as electricity and heat. Therefore, the effective diagnosis of their operating status is necessary. Crosslinked polyethylene (XLPE) is widely used as the main insulation material for cables in power systems. In this study, the microscale and macroscale performance of the molding process of XLPE cables were compared. Wireless radio frequency identification (RFID) technology was used to diagnose the aging and locate the defects of XLPE cables in the DN. The experiment noted the average insulation crosslinking degree of 88.93% and 87.98% for the suspension chain- and tower-type XLPE cables, respectively. The insulation-melting and crystallization temperatures of the suspension chain-type XLPE cable were approximately 110 °C and 92 °C, respectively, and the crystallinity was approximately 36.5%. The insulation-melting and crystallization temperatures of the tower-type XLPE cable were approximately 105 °C and 88 °C, respectively, and the crystallinity was approximately 34%. Using the wireless RFID technology, the precise positioning of the local aging and insulation damage defects in XLPE cables can be achieved. The error in locating the cable defects using the high-frequency phase spectrum of the cable was less than 0.5 m. Therefore, the study on the manufacture of XLPE cables has significant impact on the physical and chemical properties of their insulation layer. Further, the cable inspection using the wireless RFID technology provides a guarantee on the safe operation of the power system.

Standardization proposal and product design of offshore floating photovoltaic system cables

The cable product for sea surface floating photovoltaic system is a waterproof cable with a highly comprehensive performance developed from the wiring application of the land photovoltaic system, which is mainly used for the electrical connection between modules of sea surface floating photovoltaic system, as well as the electrical connection of each assembly to the combiner box and combiner box to the inverter. This work introduced the main product types of photovoltaic cables in domestic and internationally, focusing on environmental adaptability, mechanical performance, and special waterproof performance analysis. On this basis, the standardization proposal for cables used in floating photovoltaic systems on the sea was proposed to facilitate the generalization, serialization, and standardization of such products, and further introduce the corresponding product design scheme, material selection, and process control, so as to provide reference for the cable manufacturing enterprises.

The importance of accounting information in time of crisis: The Semiconductor Shortage as a result of the COVID-19 Pandemic and the impact on the Romanian Cable Manufacturing Subsector

Accounting information plays a crucial role in the decision-making process given that the primary users of this information are predominantly the company's managers. Based on the financial condition, operating results, and cash flows stated within the financial statements, managers from the automotive sector had to redesign their strategies because of the COVID-19 Pandemic followed by the worldwide semiconductor supply shortage. This study aims to analyze the decisions taken by managers from the cable manufacturing subsector in Romania, based on the information provided by the financial statements in 2018-2021, considering the crisis that the automotive sector had to face since the global vehicle sales and production rates continued to be significantly below historic levels. The results show the negative effects and disruptions caused by the dual crisis in terms of profitability and performance that will probably affect the industry beyond 2022.

Evaluation of Total Quality Management Practices on Organizational Performance of Wires and Cables Manufacturing Industries in Ondo State, Nigeria

This research focused on the evaluation of total quality management on the organizational performance of Ondo state wire and cable manufacturing Industries. A case study of Denki Wire and Cable Nigeria Limited, Akure, Ondo State. The issue of poor quality of products is a major problem in the wire and cable manufacturing industries in Nigeria which can be averted by genuine quality management for enhancing product quality. The study aimed to evaluate the extent to which the principles of total quality management implemented and the impact of total quality management principles on organizational performance. A descriptive survey research design was adopted for the study. The study relied on primary data generated by administering a structured questionnaire. The study population comprised forty-five (45) respondents from Denki Wire and Cable Nigeria Limited, Akure..The entire population was used for the study, hence, sampling was not employed. Three experts validated the instruments and a reliability of 0.86 was obtained using mean and standard deviation in answering the two research questions. The hypotheses were also tested using a t-test at 0.05 level of significance. The instrument used for data collection was a structured questionnaire titled: “Total Quality Management on Organizational Performance Questionnaire” (TQMOPQ) developed by the researchers. The study relied on primary data which was generated through the administration of a structured questionnaire. The population of the study comprised of forty five (45) respondents from Denki wire and cable Nigeria limited. The result of the study shows that implementation of total quality management practices play an important role in enhancing organizational performance. In light of these findings, the following recommended were made all the total quality management principles must be implemented in order to achieve organization goal target, organization should see total quality management principle as a continuous project which should not be ignored, all staffs should join hand in the implementation of total quality management principle in the organization in order to achieve their goal target and satisfy its customers and management should engage in frequent training of employee in order to foster its quality attainment.

Alkali Activation of Solid Waste from Cable Wire Manufacturing Industry for Building and Construction

Iron-laden tailings have received a lot of attention in recent years, especially for their potential use in civil engineering projects. Alkaline activation was studied as a method to use iron sludge from cable wire manufacturing industry (CWI). Two reagents, namely sodium silicate and sodium hydroxide concentrations of 1 M, 5 M, and 10 M were studied for alkaline activation. To make a paste, the solutions were combined with CWI waste. Using 50x50x50 mm3 molds, the paste was cast into triplicates and allowed to set. The molds were demolished once the paste had solidified, and the specimens were cured at increased temperatures and at room temperature. The specimens were cured for days, 7 days, and 14 days at ambient temperature. The specimens were subjected to geochemical and geotechnical testing after the curing period to determine the mechanism that contributed to unconfined compressive strength (UCS) development. The findings demonstrated that when the two reagents were compared, sodium hydroxide proved to be a better activator, resulting in a greater unconfined compressive strength, particularly when the specimen was cured at a high temperature. When cured at both elevated and ambient temperatures, the sodium silicate did not perform well as an activator, as the specimen were not durable.

Improved direct current electrical properties of XLPE modified by graftable antioxidant and crosslinking coagent at a wide temperature range

AbstractTo enhance the DC electrical performance of cross‐linked polyethylene (XLPE), the graftable antioxidant methacrylic acid 2‐hydroxy‐3‐(4‐anilinoanilino) propyl ester (GA), which contains carbonyl and amino groups, and the crosslinking coagent trimethylolpropane trimethacrylate (TMPTMA), which contains carbonyl groups, are individually or co‐grafted onto XLPE. The slightly higher deep trap density introduced by higher grafting concentration of TMPTMA results in more significant suppression effect of conductance current and enhanced breakdown strength at a lower temperature, while the suppression effect for the conductance current at 90°C becomes weakened due to limited trap energy. Meanwhile, the deeper energy level introduced by GA suppresses the conductance current and improves the electrical strength of XLPE at 90°C more significantly. By co‐grafting, the conductance current of XLPE in a wide range temperature can be significantly reduced, especially for the temperature dependence of conductance current, which is beneficial to suppress the field strength reversal. The results of thermally stimulated current and molecular simulation show that the polar groups of two monomers introduce deep charge traps in XLPE. The co‐grafting system ensures the rationality of the crosslinking reaction kinetics and does not affect the cable manufacturing.