Cable Production Research Articles

FEATURES OF THE STUDY OF BIMETALLIC CONDUCTORS WITH SIGNS OF A SHORT CIRCUIT

In the process of investigating fires, the version of involvement in the occurrence of burning emergency modes in electrical equipment and electrical wiring often becomes one of the main ones. The consequence of the current overload of electrical conductors is the appearance of localized short circuit melting on them. In the indicated context, the most important stage of the study is the establishment of a direct or reverse causal relationship between a fire and a short circuit. The latter is possible due to the fact that the conductor metal is able to store situational trace information in the microstructure, which fixes the parameters of the state of the metal both during its solidification and after that, together with changes in the physicochemical (primarily temperature) environmental conditions. The main materials for the production of the most common cable products at the moment are copper and aluminium, which is the reason for the fullness of the existing methodological manuals with the development of instrumental methods for establishing the moment of occurrence of short circuits relative to fire exclusively for copper and aluminium conductors. Bimetallic conductors undeservedly remained outside the field of view of specialized methodological literature. The fact that this fact is an omission is evidenced by repeated cases of receipt of melted fragments of aluminium-copper wiring as objects of expert research in investigations into the causes of fires. The article pays special attention to the design of bimetallic conductors and the related features of the morphology of the melted areas to avoid erroneous interpretation of the melting of a short circuit of an aluminium-copper, as the deposition of foreign metal on a monometallic copper conductor. Also, the purpose of this work was to provide specialists who are to investigate short circuits on bimetallic aluminium-copper conductors, including with a metallographic analysis, information missing in the specialised methodological literature regarding the structural features and chemical composition of the short circuit melting metal on conductors of this type. An example from the expert practice of studying bimetallic (aluminium-copper) conductors with signs of a short circuit is given. The data presented in the article are based on studies using optical and scanning electron microscopy. Key words: metallographic analysis, short circuit, forensic fire expert, overcurrent, melting, bimetal, wiring.

Application of Intumescent Coating for Increasing Fire-Resistance Values of Cable Products

The results of experimental studies on the effectiveness of insulation of electrical cables with fire-resistant coating are presented. Analysis of methods of cables products using shows a steady trend of increasing their using during the arrangement of premises. Fires and rapid spread of flame are possible during the exploitation of such structures. Statistics of cable products show a low level of safety due to using of combustible insulation, which is highly sensitive to high temperatures and fire. After the test, it is seen that the specimen of the cable without a fire-resistant coating supports self-combustion for more than 30 s, and the damage to the specimen is more than 100 mm. After testing the specimen with a fire-resistant coating, it is seen that the cable specimen doesn’t support self-combustion, and the damage to the specimen isn’t more than 40 mm. Inhibition of the process of ignition and propagation of flame for such specimen is associated with the decomposition of flame retardants under the action of temperature, which occurs with heat absorption and release of non-combustible gases (nitrogen, carbon dioxide), as well as changing the direction of decomposition towards non-combustible gases and flame retardant coke residue. This leads to an increase of the thickness of the coke layer and inhibition of heat transfer of high-temperature flame to the insulation material, which indicates the possibility of transition of combustible insulation of the cable with a fire-resistant coating to non-flammable materials, which aren’t spread a flame.

Study of physical control methods for metric parameters of extended products in cable industry

The paper discusses the problems of electrical cables metric (geometric) parameters measurement. The methods of measuring the eccentricity of the electric cables (contact, ultrasonic, X-ray, and inductive-optical) are considered. The advantages and disadvantages of using these methods of technological control of cable products are shown. A study of the inductive-optical conversion method for measuring the eccentricity of a singlecore cable, including the circuit for switching on the windings of the inductive converter, is proposed; the design of this converter is presented. The proposed solution makes it possible to achieve good conversion linearity when the conductor is displaced in the control zone. Wherein there is no need to use a system of mechanical drives for centering the magnetic transducer. In addition, the proposed scheme enables to combine the magnetic and optical transducer constructively in the same plane, which ensures to reduce its longitudinal dimensions relative to known analogues. The device prototype for eccentricity control is created based on the proposed transducer; its technical characteristics are confirmed. Direction of further research is determined as part of the development of the industrial design of the device.

DEVELOPMENT OF A MATHEMATICAL MODEL OF THE "SHROEDER-TRANSPORTER" SYSTEM IN THE TECHNOLOGY OF PROCESSING CABLE WASTE

The article deals with the development of a mathematical model of the "Schroeder - Transporter" system, which is the main part of the technological process of processing waste cable and wire products. The task of increasing the efficiency of the cable waste recycling process is solved by optimizing the operation of all electromechanical systems: crushers, shredders, granulators and their connecting elements - conveyors. The very process of moving crushed cable production waste has an unstable nature of the load of the moving web, and the reduction of dynamic loads during the start-up of the electromechanical system of the conveyor, the transfer of cargo from one crushing equipment to another is very important. The solution is to control the operating modes of the conveyor by the speed parameters of the tape movement and the change in dynamic loads in case of uneven loading and movement of the flow of the crushed cable mass. The mathematical model of the electromechanical system "Conveyor - shredder" is based on the study of the movement of the tape, which will take into account the uneven traffic, as well as the presence of large and unstable dynamic effects. The choice of modeling parameters is also determined by the flow of processes in the conveyor belt with variable loads and will ensure that the elastic-viscous properties of the entire system are taken into account when the load is transferred along the conveyor in compliance with the speed parameters that are optimal for the operation of the entire waste processing line.

Influence of nanofiller concentration on polypropylene nanocomposites for high voltage cables

Abstract Polymeric insulation for HVDC cable is attracting more attention in the modern power transmission system. Especially, the thermoplastic material is desirable for power cable insulation because of its recyclability and ease of processing. Thermoplastic material development is a good alternative to cross-linked polyethylene in the future. Polypropylene has the advantage of avoiding by-products during cable production, which can minimize space accumulation and degassing costs. Therefore, this study investigates the influence of nanofillers on the structural properties of isotactic polypropylene. In addition, the proposed composite material’s morphology, melting, dielectric permittivity, and breakdown strength are examined. Different weight percentages of inorganic nanofillers such as TiO2 and ZnO are used to make nanocomposite thin films. With increasing filler concentration, the dielectric constant of the nanocomposite thin film increases. Apart from that, the dielectric loss of the TiO2 nanocomposite thin film increases with weight percentage initially and it falls nearer to virgin material at a higher frequency. The breakdown strength of the nanocomposite materials shows a similar variation with filler concentration. TiO2 is more resistant to deterioration than ZnO composite. Based on the results of the complete investigation, the TiO2 nanocomposite is better suited for the insulation of HVDC cables.

Strategic management of the enterprise: analysis of sectoral determinants

The article proposes a methodology for determining and analyzing the determinant of the development of the industry, which makes it possible to formulate a list of applied recommendations for the formation of a strategy for the development of enterprises in the cable industry. The study uses a number of methods, the use of which allows us to explore the strategic prospects for the development of the industry, identify the determinants of development, evaluate them, and establish the nature of the impact on the activities of enterprises in the industry; highlight the structural and logical relationships between the studied factor conditions and development determinants, substantiate practical recommendations on the formation of a development strategy for enterprises in the industry. These methods include: methods of analyzing time series, methods of expert evaluation, the rhombus of state advantages by Porter, graph-analytical methods.The article provides statistical data on the volume of the world market for cable and wire products, identifies the main manufacturers and exporters of cable products. Trends in changes in the volume of production and sales of cable products in the world and in Ukraine are studied, in particular, the prospects for the development of the industry are substantiated. The main determinants of the development of the cable industry are determined, which are systematized and studied by the rhombus method of national advantages by M. Porter. Based on the method of expert assessment, a linguistic assessment of the established determinants is carried out, and the nature of their influence on the activities of enterprises in the industry is determined; the structural relationships between the studied factor conditions and development determinants are studied. The article provides arguments for choosing this particular methodological approach to analysis, which, on the one hand, makes it possible to ensure the complexity of the study - taking into account the systematic identification of determinants, the ability to take into account dynamic changes, determine the nature of their influence and track the structural and logical relationships between the studied factor conditions and development determinants. industries. Based on the results obtained, the author makes practical proposals for the formation of a strategy for the development of Ukrainian enterprises for the production of cable and wire products in the global and domestic markets.

Оценка токсичности не распространяющих горение сигнальных кабелей при пожаре в производственных помещениях

Currently, flame retardant materials made from polymers with flame retardant additives are widely used. However, the thermal effects of the fire on these materials from the point of view of the release of toxic gases are not sufficiently studied. The purpose of the article is an experimental assessment of the toxicity of the gaseous environment of a room during thermal decomposition of flame retardant signal cables used in the industrial premises and in the buildings with a massive presence of people. Experimental method is used for studying the process of formation of the hydrogen cyanide and carbon monoxide during thermal decomposition of the cable product samples in a small-scale pilot plant. The analysis of the obtained results was carried out. Density of the radiant heat flux incident on the cable surface, which is characteristic of a fire in a room, is modeled. Dependences are obtained concerning the partial densities of hydrogen cyanide and carbon monoxide, as well as the specific emission coefficients of these gases on the duration of experiments in the case of thermal decomposition of a modern flame retardant signal cable of the ng LS FR HF E1180 brand, the insulation of which is made of polymers with flame retardant additives. It is found that this cable under real fire conditions can release toxic compounds (carbon monoxide and hydrogen cyanide) in the concentrations exceeding their maximum allowable values during the evacuation of people from the premises. The obtained values of the specific mass coefficients of formation of CO and HCN, as well as the specific mass coefficient of O2 absorption, can be used in the mathematical models of the dynamics of fire hazards when calculating the time of blocking escape routes in the industrial premises, as well as in the buildings with a mass stay of people, where flame retardant signal cables are located.

Developing a Novel Fully Automated Concept to Produce Bowden Cables for the Automotive Industry

The automotive industry is one of the driving forces of the global industry; thus, it is a very competitive sector which creates a constant need for process improvement, regarding productivity, quality, and flexibility. Automation has proven to be a viable solution for these production problems, with the rising adoption of these automated system by companies that try to design and implement more flexible systems, while reducing costs and improving process quality. Furthermore, the use of automation reduces the manpower factor and its associated variability. In the present work, a new concept for a Bowden cable production process is presented by employing the design science research (DSR) methodology. The project starts with the analysis of the previous production concept, determining possible problems and improvements, as well as setting objectives/requirements for a possible new concept/equipment. This information was used to develop a new automated Bowden cable production equipment, implementing several changes to the old concept and filling a gap in the literature in this field. The developed system was implemented and tested. A considerable reduction in cycle time was registered by 25%, which resulted in an increase of 30% in process productivity.

Application of Conductor Preheating Device in the Production of XLPE CABLE

Application of Conductor Preheating Device in the Production of XLPE CABLE

Influence of doping additive on thermophysical and rheological properties of halogen-free polymer composition for cable insulation and sheaths

Introduction. The demand for halogen-free fire-resistant compositions for the manufacture of fire-retardant wires and cables is constantly growing. Problem. Therefore, the creation and further processing of these materials is an urgent problem. Goal. The aim of the article is to study the effect of the doping additive on the thermophysical and rheological properties of halogen-free compositions for power cables with voltage 1 kV with the determination of both the temperatures of phase and structural transformations of polymer compositions. Methodology. Experiments investigating the phase transformations were carried out with the help device of thermogravimetric analysis and differential scanning calorimetry TGA/DSC 1/1100 SF of METTLER TOLEDO company. Rheological studies of polymeric materials were conducted by using the method of capillary viscosimetry in the device IIRT–AM. Results. The influence of the doping additive on the formation of the supramolecular structure of the filled polymer compositions for cable products was determined, that resulted in the temperature increase of the decomposition beginning by 11 °С and the end of decomposition by 7 °С. Originality. The effect of a doping additive on reducing the effective melt viscosity of a polymer composition from 6·104 to 1·104 Pa·s with increasing shear rate has been shown for the first time. The shear rate of the polymer composition containing the doping additive increases from 0.5 to 20 s–1 with increasing shear stress. Practical value. The research results provide an opportunity to reasonably approach the development of effective technological processes for the manufacture of the insulation and sheaths of power cables from halogen-free polymer compositions.

Effects of Pre-Bunching Trees With a Tethered Feller-Buncher on Cable Logging Productivity and Costs: A Case Study in Southern Oregon

AbstractWinch-assist or tethered logging technology is rapidly being adopted by the forest industry across the western United States to replace conventional and dangerous manual tree falling in cable logging areas. Although the safety benefits of the technology are widely acknowledged, the effects of tethered mechanized timber falling and pre-bunching on the subsequent cable yarding operations have not been thoroughly investigated. We conducted a field study in southern Oregon to compare manual versus mechanized timber falling side-by-side for their impacts on the productivity and costs of cable logging operations. Our study shows that the costs of mechanized timber falling were higher than manual falling owing to high costs of tether equipment, but the ability of the felling machine to pre-bunch trees into piles along designated skyline corridors made subsequent cable yarding operations significantly more efficient. The efficiency gained during yarding was sufficient not only to offset cost increase in felling but also to reduce the total production costs of felling and yarding operations by 32% compared with cable yarding after manual timber falling.

Application of Edge Computing in the Quality Control of Cable Production Process

Given the lack of quantifiable evaluation criteria for the quality supervision and control in the existing power cable industry, insufficient research on the correlation of production indexes in the production process, and low timeliness in the analysis and processing of massive multi-source production data, the video monitoring model and data-driven process quality evaluation strategy model under the edge computing framework were constructed. Next, all the production data and test data in the cable production procedures were captured using edge nodes, and the factory-side data was cleansed, processed, and analyzed. The cable manufacturing quality was evaluated through edge computing, and the business process was arranged based on the edge computing results, so as to improve the cable product quality and finally optimize the total value chain of production in the whole cable industry.

Analisis Kinerja Plant Produksi PT. JCC Dengan Menggunakan Perhitungan Overall Equipment Evectiveness (OEE)

PT. JCC Established in April 1973, PT Jembo Cable Company Tbk. started by producing Low Voltage Electrical Cables - copper conductors. Then continue to add product varieties, such as Low Voltage Cable - aluminum conductor, Medium Voltage Cable, Telephone Cable and Fiber Optic Cable and also expand its market. Production Plant performance can be improved or maintained by conducting regular evaluations of the process. The evaluation carried out is by analyzing OEE (Overall Equipment Effectiveness). OEE (Overall Equipment Effectiveness) is a calculation method used to determine the effectiveness of a process that is being implemented by identifying the percentage of production time that is truly productive which is influenced by three factors, namely availability, performance, and quality. reached 85% or above. The research was conducted by observing the cable production process at the Aluminum Cable Plant and the Copper Cable Plant. Based on the observations made from January 2021 to June 2021, the highest OEE value was obtained for the Aluminum Cable Plant in January and February, namely 97% and 94% while for the next month below 90%. For the Copper Cable Plant, since observing from January 2021 to June 2021, it has not yet reached the required OEE value, which is 85% and above. From the results of the analysis, the main factor is not achieving the OEE Value influenced by the low availability ratio It's because almost 50% of the machines in the Aluminum Cable Plant and 25% of the machines in the Copper Cable Plant don't get a workload.

Capacity Analysis of Cable Insulation Crosslinking Production Process Based on IoT Big Data

In the cable insulation crosslinking production process, the process quality is determined by multiple processes and multiple related process variables, and there are complex autocorrelation and cross-correlation among these process variables. In this paper, different process variables are studied. By implementing statistical process control on a univariate, single value control chart (I) and moving range control chart () are drawn, and process capability CP is analyzed to find variables with weak process capability for improvement. At the same time, based on the background of the continuous development of the Internet of Things and big data technology, this paper evaluates the complex autocorrelation and cross-correlation between the overall process variables, adopts the multivariate statistical process control technology, and combines the multivariate HOTELLING T2 control chart and MEWMA control chart to reflect the statistical characteristics of multiple variables, thus avoiding misjudgment or omission of process quality monitoring model. By studying the setting of cable production process parameters and quality standards, combined with the application of complete multivariate statistical process control (MSPC) around the evaluation results, process, and technical requirements, this research can provide effective guidance for the cable insulation crosslinking production process

Vision-Based Productivity Analysis of Cable Crane Transportation Using Augmented Reality–Based Synthetic Image

The productivity analysis of cable crane transportation in the construction field is of great significance to improve crane equipment management and reduce operation costs. However, the traditional manual recording method of analyzing cable crane productivity is time-consuming and tedious. The existing vision-based method requires significant amounts of time to collect extensive images at construction sites and does not achieve high-precision detection in complex scenes. Thus, an automated vision-based method for productivity analysis of cable crane transportation is proposed using a new synthetic image approach based on an augmented reality (AR) technique. The unmanned aerial vehicle-based three-dimensional (3D) reconstruction of a crane bucket model is superimposed on a realistic scene using AR to synthesize the images for vision-based model training without manual image acquisition at a construction site. The feature pyramid network and attention module are integrated into Faster region-based convolutional neural network (Faster R-CNN) to enhance the capability of feature extraction for the high-precision detection of a crane bucket and its ID number, which provides the logical basis for calculating productivity. The proposed vision-based productivity analysis method is evaluated on large-scale hydraulic engineering. The results demonstrate that the mean average precision (mAP) of detection performance is 98.01% using the model trained by AR-based synthetic images, which confirms the proposed AR-based synthetic image method could provide a new image generation mode for the construction industry. Additionally, the bias of productivity between the proposed method and ground truth is 0.03%, which confirms the effectiveness and accuracy of the proposed method.

ИСПОЛЬЗОВАНИЕ СОВРЕМЕННЫХ ИНСТРУМЕНТОВ МЕНЕДЖМЕНТА КАЧЕСТВА ДЛЯ ПРИНЯТИЯ ЭФФЕКТИВНЫХ УПРАВЛЕНЧЕСКИХ РЕШЕНИЙ

Abstract. The article systematically examines the problems of using quality management tools to make informed management decisions. The use of FMEA analysis to analyze the types and consequences of possible damages in relation to the production of cable products is considered.

Modeling the formulation of the PVC cable composition

Increasing the fire-retardant characteristics of polymeric cable materials has attracted the close attention of experts all over the world for many years, since fires are often associated with the ignition of cable products, followed by the spread of fire through cable communications. In this regard, the development of new modern formulations of fireproof compositions with improved performance properties is especially relevant for the production of PVC cable composites. The article describes the production of a new phosphorus-containing flame retardant phenyldixylol phosphate and investigated its physicochemical properties. The new flame retardant was tested in an industrial formulation of a PVC cable composition using dibutoxyethyl adipate as a plasticizer. Using the methods of correlation-regression analysis and optimization, the optimal ratio of the resulting additive and tricresyl phosphate was selected, which provides the best technological and operational parameters of the PVC composite.

Features of technology of manufacture of power high voltage cables with thermoplastic polymeric insulation

The problem of high-voltage power cables is associated with complex technological processes in their manufacture. One of the main processes in the manufacture of cables is extrusion. There is a huge number of parameters (known as process parameters) at the stage of extrusion process that directly affect the performance of isolation and cable as a whole. It is shown that the important parameters of the process of extrusion are the melt temperature, speed, pressure, screw speed, the type of matrix used and the cooling medium in the extruder. The temperature and pressure of the melt are among the largest important parameters in the process of extrusion that determine the productivity of the process. The influence of temperature, pressure and fluctuations of these parameters on a complex of mechanical and electrical characteristics of the cable are analyzed. It is substantiated that the rheological properties of polymers are prone to oscillations, which causes problems in the production of cables. The complexity and large number of process parameters involved in the production of cables are complicated by the process of control, which determines the appearance of defects in the form of cracks, air cavities and porosity in high-voltage isolation. It is argued that the use of power cables with a cross-linked polyethylene, which is a thermosetting insulating material, causes the complexity of processing both in the manufacturing stage and in operation. Development of technology for the introduction of thermoplastic isolation provides secondary processing to implement projects of power-high-voltage variable and direct current cables. A comparative analysis of electrical, mechanical and thermal parameters of cross-linked polyethylene and thermoplastic polymers as an alternative of thermosetting isolation is presented. The article presents the features of the technological regime of extrusion of polymer isolation based on thermoelastoplasts, in particular, polypropylene compositions, which are due to the lower values of the coefficient of thermal conductivity of such compositions in comparison with polyethylene. Models are presented to describe the process of extrusion of thermoplastic isolation of power cables, taking into account the flow of molten polymeric material as a non-Newtonian, uncompressive, isothermal fluid. The necessity of determining the values of the coefficients of thermal conductivity and heat capacity of polypropylene compositions in a wide temperature range to reduce the likelihood of technological defects in high-voltage thermoplastic isolation is substantiated.

INVESTIGATION OF THE EFFECT OF BORON NITRIDE AND COLEMANITE ON THE PROPERTIES OF POLYVINYL CHLORIDE

Polyvinyl chloride (PVC) is used as an insulator in cable production. In order to enhance its thermal stability and flame retardant properties various chemicals have been added to PVC. In this study, hexagonal boron nitride (BN) and colemanite (C) at different concentrations were added to PVC to prepare composites by melt compounding method. The effect of formulation on the properties of PVC composites were observed. The thermal stability of PVC composites was determined by using a PVC Thermomat device. LOI (Limiting Oxygen Index) tests were performed to examine combustion characteristics. The mechanical properties of the composites were conducted by tensile tests. BN and C had a positive effect on the thermal stability of PVC. PVC remained stable for 3.74 hours at 210°C. Addition of BN and C (1 wt.% of the amount stabilizer) increased stability time to 4.16 hours, and 5.50 hours, respectively. The composite in which BN and C were used together remained stable for 5.74 hours. LOI value of BN and C added composite did not change noticeably, compared to neat PVC. The mechanical properties of composites remained within acceptable limits for being used in cable production. In brief, addition of BN or C to PVC is an effective technique to produce cables with improved properties for various applications.

PENGENDALIAN KUALITAS TWISTED CABLE DENGAN METODE SEVEN TOOLS DAN QUALITY CONTROLCIRCLE (QCC) DI PT VOKSEL ELECTRIC Tbk

Production planning increases every month, with the increase in planing it is necessary to improve quality. PT Voksel Electric Tbk is a manufacturing industry engaged in the production of power cables, telecommunications, and fiber optics. The company tries to control the quality of its products to maintain quality in accordance with the company's vision, which is to become a world-class cable solution provider in Indonesia. The purpose of this study was to determine how to control the quality of Twisted Cable at PT Voksel electric Tbk using the seven tools and QCC methods. The increased production planning does not match the actual production . This is due to the level of production failure. In this study, the method used in quality control is seven tools that are used to analyze the causes of production failure rates. By using the PDCA cycle (plan, do, check, action) and by using seven tools as a tool to determine the cause and effect of the failure of the production process. The causes obtained are from gram dust, from crust on visual insulation, and from powder materials. By controlling the quality using the seven tools method, it can reduce production process time, production costs, and increase production capacity from 700 km to 800 km. an increase in production capacity of 100 km provides a benefit of
 Rp. 470,000,000,00,-