Electrical Power Cable LV PVC & Mv XLPE Insulation Copper/Aluminum Core Industrial Cable 1-300mm² Custom Sizes

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2025-08-28 03:55:42

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Introduction du produit

Comprehensive Details of LV PVC & MV XLPE Insulated Copper/Aluminum Core Industrial Power Cables (1-300mm² Custom Sizes)

I. From the Perspective of the Product Itself

(I) Specification Parameters

Voltage and Insulation Matching Specifications
Low-Voltage (LV) PVC-insulated series cables strictly comply with LV power distribution system standards, with core rated voltages covering 0.6/1kV (phase voltage 0.6kV, line voltage 1kV). For specific scenarios, 0.45/0.75kV specifications can be customized to adapt to mixed civil and industrial LV power supply networks. The insulation thickness of this series is precisely designed based on cross-sectional area: 0.6mm-0.8mm for small-specification cables (1mm²-10mm²), 0.8mm-1.2mm for medium-specification cables (16mm²-70mm²), and 1.2mm-1.6mm for large-specification cables (120mm²-300mm²). This ensures stable insulation performance under rated voltage, and all cables pass the insulation withstand voltage test specified in GB/T 12706.1-2020, with no breakdown when subjected to 1.8kV for 1 minute.

Medium-Voltage (MV) XLPE-insulated series cables cover three mainstream rated voltage specifications: 6kV, 10kV, and 20kV, each adapting to industrial MV power transmission scenarios of different scales. The 6kV specification is mainly used for internal MV power distribution trunks in small and medium-sized factories, such as power supply for heavy machine tools in machinery plants; the 10kV specification is suitable for outgoing lines of substations in large industrial parks, connecting power distribution systems of various branch factories; the 20kV specification is applied in high-voltage industrial scenarios, such as power supply for large arc furnaces in metallurgical plants. The insulation thickness of Mv Cables is designed differently according to voltage levels: 3.4mm for 6kV, 4.5mm for 10kV, and 6.0mm for 20kV. The insulation layer adopts a three-layer co-extrusion process (inner semi-conductive layer + insulation layer + outer semi-conductive layer). The inner semi-conductive layer eliminates electric field concentration on the conductor surface, and the outer semi-conductive layer closely combines with the metal shielding layer, further improving insulation reliability. The partial discharge quantity is ≤10pC (under 1.73 times the rated voltage), far lower than the 50pC required by national standards.
2. Conductor Specifications and Current-Carrying Capacity
Conductors are available in copper and aluminum cores, with both covering a cross-sectional area range of 1mm²-300mm². Their current-carrying capacities have been certified by authoritative institutions. For copper-Core Cables, the 1mm² copper-core cable has a current-carrying capacity of 12A when laid in air and 14A when laid in soil at 25℃, suitable for industrial control lines or power supply for small instruments (such as sensors and indicator lights); the 2.5mm² copper-core cable has a current-carrying capacity of 25A in air and 29A in soil, which can be used as workshop lighting lines (total power of a single lighting circuit ≤5kW) or power supply lines for small fans (power ≤3kW).

The 16mm² copper-core cable has a current-carrying capacity of 85A in air and 98A in soil, adapting to LV motors below 50kW (such as water pump motors and conveyor belt motors); the 70mm² copper-core cable has a current-carrying capacity of 215A in air and 240A in soil, applicable to power supply for MV motors of 100kW-150kW; the 300mm² copper-core cable has a current-carrying capacity of 620A in air and 680A in soil, suitable for outgoing lines of large transformers (capacity ≥1000kVA) or main power distribution trunks in factories. The current-carrying capacity of aluminum-core cables is approximately 80% of that of copper-core cables of the same specification: the 1mm² aluminum-core cable has a current-carrying capacity of 9.6A in air and 11.2A in soil; the 16mm² aluminum-core cable has 68A in air and 78A in soil; the 300mm² aluminum-core cable has 496A in air and 544A in soil. Although its current-carrying capacity is slightly lower, in long-distance laying scenarios (such as cross-factory lines over 1km), its lightweight advantage is significant, reducing line erection costs and difficulties.

In addition, the conductor structure is optimized based on cross-sectional area: 1mm²-10mm² adopts a bunched structure (multiple strands of fine copper/Aluminum Wires bundled together) to improve Flexibility, facilitating bent wiring inside equipment; 16mm²-70mm² uses a regular stranding structure, ensuring high conductor roundness and reducing insulation thickness deviation; 120mm²-300mm² adopts a split conductor structure (the conductor is divided into 3-4 sub-conductors, each insulated independently before stranding), which effectively reduces the skin effect and proximity effect, minimizing power loss during current transmission. The AC resistance of 300mm² split-Conductor Cables is reduced by more than 15% compared to ordinary Stranded Conductors.
3. Core Count and Sheath Specifications
The product offers multiple core count options, including 1-Core, 2-core, 3-core, 4-core, and 5-core, to meet different power supply requirements. 1-core cables are mainly used for high-voltage motor power supply or large-current transmission scenarios, such as 20kV/300mm² 1-core cables for power supply of arc furnaces in metallurgical plants; 2-core cables are suitable for single-phase LV equipment, such as industrial single-phase welding machines (power ≤20kW); 3-core cables are used in three-phase three-wire power supply systems, such as three-phase power supply for high-voltage motors and transformers; 4-core cables adopt a "3+1" structure (3 phase wires + 1 neutral wire), suitable for three-phase four-wire LV power distribution systems, such as mixed power supply for workshop power and lighting; 5-core cables use a "3+1+1" structure (3 phase wires + 1 neutral wire + 1 Grounding Wire), eliminating the need for additional grounding wire laying, and are applicable to scenarios with high safety grounding requirements, such as power supply for explosion-proof equipment in chemical workshops.

Sheath materials are customized according to scenario needs: regular sheaths use PVC materials, which have good wear resistance and weather resistance, suitable for general industrial environments; for scenarios with oil pollution (such as chemical workshops), oil-resistant Rubber Sheaths are selected, with a volume change rate ≤5% and hardness change ≤10 Shore A after soaking in No. 10 machine oil for 72 hours; for high-rise buildings or densely populated areas, low-smoke halogen-free polyolefin sheaths are adopted, with a smoke density rating (SDR) ≤60 and halogen acid gas emission ≤5mg/g when burned, complying with GB/T 17650.2-1998; for mining or buried laying scenarios, a Steel Tape armoring + PE sheath structure is used, with a steel tape thickness of 0.8mm-1.2mm and soil pressure resistance ≥30kN/m, preventing damage from gravel extrusion during burial.

(II) Characteristic Applications

Application in the Machinery Manufacturing Industry
In the machinery manufacturing industry, this cable can meet the full-link needs from equipment control to power transmission. For control lines and lighting lines of small machine tools (such as lathes and milling machines, power ≤10kW), LV PVC-insulated copper-core cables of 1mm²-2.5mm² are selected, which have good flexibility and can adapt to complex wiring paths inside the equipment; for Power Lines of medium-sized machine tools (such as boring machines and grinding machines, power 10kW-50kW), LV PVC-insulated copper-core cables of 16mm²-25mm² are used, whose current-carrying capacity matches the power of machine tool motors, and the PVC Insulation layer is resistant to machine oil corrosion, adapting to the machine tool working environment.

For power supply of large heavy machine tools (such as gantry milling machines and forging presses, power ≥100kW), MV XLPE-insulated copper-core cables are required, such as 10kV/70mm² Cables, which can stably transmit large currents. The XLPE insulation layer has good temperature resistance, adapting to the high-temperature environment generated by long-term high-load operation of machine tools; for power distribution trunks in machine tool workshops with long laying distances (over 500 meters), aluminum-core cables (such as 10kV/120mm² aluminum-core cables) can be selected, which meet current-carrying requirements while reducing line procurement and erection costs. In addition, for power supply of moving parts of machine tools (such as telescopic arms and rotating worktables), soft-state conductor cables (annealed) can be used, with a bending radius reduced to 6 times the cable outer diameter, avoiding conductor breakage caused by frequent bending.
2. Application in the Chemical Industry
The chemical industry has special requirements such as high temperature, corrosion, and explosion prevention, and this cable can be accurately adapted through material customization. For power supply of reactors (power 50kW-150kW) in chemical workshops, if there are acid-base vapors around the reactor, MV XLPE-insulated copper-core cables are selected, and the outer sheath is made of fluororubber. After soaking in 20% hydrochloric acid and 30% sodium hydroxide solutions for 72 hours, the fluororubber sheath shows no significant change in insulation performance and has explosion-proof characteristics (complying with GB 3836.1-2021), avoiding explosion risks caused by cable faults.

For power supply of oil pipeline heating systems in chemical parks, which need to withstand high-temperature environments (pipeline surface temperature ≤80℃), XLPE-Insulated Cables are selected, with a long-term operating temperature of 90℃, ensuring stable operation; for instrument control lines in the park (such as flow sensors and liquid level gauges), LV PVC-insulated copper-core cables of 1mm²-4mm² are used, with an anti-interference shielding layer (Copper Wire braided shielding, shielding coverage ≥90%) added to avoid electromagnetic interference from chemical equipment affecting instrument accuracy. For power supply of submersible pumps in chemical wastewater treatment workshops, waterproof cables (IP68 protection level) are adopted, with sheaths made of neoprene rubber. After soaking in 1-meter deep water for 24 hours, the insulation resistance is ≥100MΩ, ensuring safe underwater power supply.
3. Application in the Metallurgical Industry
The high-temperature and high-dust environment of the metallurgical industry imposes strict requirements on cable performance, and the high-temperature resistance and protection design of this cable can be effectively adapted. For power supply of blast furnace blowers (power ≥200kW) in ironmaking plants, MV XLPE-insulated copper-core cables of 20kV/240mm² are selected. The XLPE insulation layer has a temperature resistance of 90℃, which can withstand the high temperature generated by the blower operation, and the cable outer sheath is made of high-temperature resistant silicone rubber, which shows no aging after long-term use in a 150℃ environment; for power supply of converter tilting systems in steelmaking workshops that require frequent movement, cables with soft-state conductors and wear-resistant sheaths are selected. The conductors are made of bundled multiple strands of fine copper wires (each strand diameter 0.2mm), and the sheaths are made of polyurethane, with wear resistance reaching no damage after 100,000 friction cycles.

For power supply lines of raw material conveyor belts in metallurgical plants with high dust levels, steel tape armored + PVC Sheathed Cables are used. The armor layer prevents dust from entering the cable interior and causing insulation damage, and the PVC Sheath is easy to clean; for power distribution trunks from the substation to various workshops in the plant with long distances (usually 1km-3km) and large current-carrying capacity, 300mm² aluminum-Core XLPE-Insulated Cables are selected. The lightweight aluminum core reduces the load-bearing requirements of the poles for Overhead Lines, and the low dielectric loss characteristic of the XLPE insulation layer reduces power loss during long-distance transmission.
4. Application in the Construction Industry
In temporary power supply and fixed power distribution scenarios in the construction industry, the diverse specifications of this cable can meet the needs. For temporary construction power supply in construction sites (such as tower cranes and concrete mixers) with power usually 50kW-150kW, LV PVC-insulated copper-core cables of 16mm²-70mm² are selected. The PVC insulation layer has good weather resistance, adapting to outdoor environments exposed to wind and sun, and the cables can be coiled for storage, facilitating construction movement.

For permanent power distribution systems in high-rise buildings, such as power supply for central air conditioning hosts (power ≥100kW) in office buildings, MV XLPE-insulated cables of 10kV/120mm² are selected. The XLPE insulation layer has a small volume and light weight, facilitating laying in building shafts; for emergency lighting lines in high-rise buildings, low-smoke halogen-free flame-retardant PVC-insulated cables are used, complying with the fire protection requirements of GB 50016-2014 (2018 edition). They can maintain power supply for more than 1 hour in fire accidents, release less smoke and no toxic gases, and gain time for personnel evacuation. For power supply lines of charging piles in underground garages of buildings, waterproof cables (IP67 protection level) are selected to avoid insulation damage caused by the humid environment of the garage. The cross-sectional area is selected according to the charging pile power: 6mm² cables for 7kW charging piles and 25mm² cables for 120kW fast-charging piles.

(III) Material and Style

Detailed Explanation of Core Materials
In terms of Insulation Materials, the PVC Insulation Material for the LV series uses environmentally friendly polyvinyl chloride resin, with additives such as plasticizers, stabilizers, and flame retardants added. Among them, di(2-ethylhexyl) phthalate (DOP) is selected as the plasticizer to improve the flexibility of the insulation layer; calcium-zinc composite stabilizers are used instead of traditional lead salt stabilizers, complying with RoHS environmental requirements; a composite system of antimony trioxide and chlorinated paraffin is used as the flame retardant, with an oxygen index ≥30%, meeting the flame retardant requirements of GB/T 18380.3-2008 (in the vertical burning test, the flame spread height ≤2.5m and self-extinguishing time ≤60 seconds). The dielectric loss tangent value of the PVC insulation material is ≤0.08 (20℃, 50Hz), and the insulation resistance is ≥10¹³Ω·cm, ensuring stable insulation performance in LV scenarios.

The XLPE Insulation Material for the MV series uses high-density polyethylene (HDPE) as the base resin, with additives such as cross-linking agents (dicumyl peroxide, DCP), antioxidants (pentaerythritol tetrakis[β-(3,5-di-tert-butyl-4-hydroxyphenyl)propionate], 1010), and UV absorbers (2-hydroxy-4-methoxybenzophenone, UV-9) added. The cross-linking agent decomposes to generate free radicals at high temperatures, causing cross-linking reactions of polyethylene molecules to form a three-dimensional network structure; the antioxidant delays the aging of the insulation layer and improves long-term stability; the UV absorber protects the insulation layer from UV radiation damage, adapting to outdoor laying scenarios. The dielectric loss tangent value of the XLPE insulation material is ≤0.003 (100℃, 50Hz), the insulation resistance is ≥10¹⁴Ω·cm, and the breakdown field strength is ≥20kV/mm, with all performance indicators superior to traditional PVC insulation materials.

In terms of Conductor Materials, the Copper Core uses high-purity electrolytic copper rods (copper content ≥99.95%) with a resistivity ≤0.017241Ω·mm²/m (20℃), complying with GB/T 3952-2016. The copper rods are made into conductors through multiple processes such as wire drawing (wire drawing speed 8-12m/s), annealing (annealing temperature 380℃-420℃, nitrogen protection), and stranding. Imported wire drawing oil is used during the wire drawing process to ensure the copper wire surface is smooth and free of burrs; annealing treatment eliminates internal stress generated during wire drawing and improves copper wire flexibility. The elongation of soft-state Copper Conductors is ≥30%, and that of hard-state Copper Conductors is ≥15%.

The aluminum core uses high-purity aluminum rods (aluminum content ≥99.7%) with trace alloying elements such as 0.5% magnesium and 0.3% silicon added to form 6061 aluminum alloy material, with a resistivity ≤0.028264Ω·mm²/m (20℃). Its mechanical strength is 40% higher than that of pure aluminum (tensile strength ≥120MPa), and it shows no obvious corrosion in the neutral salt spray test (5% sodium chloride solution for 480 hours). The aluminum rods also undergo wire drawing, annealing, and stranding processes. The surface of the drawn Aluminum Wires is coated with a layer of conductive paste to reduce the contact resistance between the aluminum wires and terminals, avoiding heating hazards.
2.Style and Installation Adaptation

Based on different installation methods, the product offers multiple optimized styles. For overhead installation scenarios, a "lightweight steel tape armoring + PE sheath" style is adopted. The steel tape thickness ranges from 0.5mm to 0.8mm, and the weight is 20% lower per meter compared to heavy-duty Armored Cables, facilitating overhead erection. The PE sheath is UV-resistant, making it suitable for long-term outdoor exposure. For underground burial scenarios, a "double-layer steel tape armoring + thickened PE sheath" style is used. The inner steel tape is spirally wound, and the outer steel tape adopts an interlocking armoring structure, with soil pressure resistance ≥30kN/m. The PE sheath thickness is 2.0mm-2.5mm, preventing puncture by sharp objects in the soil and making it suitable for underground distribution trunks in factories.

For conduit installation scenarios, an "unarmored + smooth PVC sheath" style is selected. The sheath surface roughness is ≤0.8μm, reducing friction resistance during conduit insertion and facilitating installation in steel or PVC pipes. For internal equipment wiring scenarios, a "soft conductor + thin-walled PVC sheath" style is applied. The conductor stranding pitch is reduced to 8-10 times the outer diameter, and the sheath thickness is 0.5mm-0.8mm, allowing a bending radius as low as 6 times the cable outer diameter, which is suitable for bent wiring in narrow spaces inside equipment. For explosion-proof scenarios, a "copper wire shielding + flame-retardant rubber sheath" style is used. The copper wire shielding layer (shielding coverage ≥90%) eliminates the leakage of electric sparks, and the flame-retardant rubber sheath (oxygen index ≥35%) prevents flame spread, complying with the explosion-proof requirements of GB 3836.2-2021 and suitable for explosion-proof workshops in the chemical industry.

(IV) Production Process

Conductor Manufacturing Process
Copper core conductor production starts with electrolytic copper rods (8mm in diameter). First, continuous wire drawing machines perform multi-pass wire drawing. The wire drawing machines adopt a frequency conversion speed control system, and the area reduction rate of each pass is controlled between 15% and 20% to ensure uniform copper wire diameter (deviation ≤±0.01mm). After wire drawing, the copper wires enter an annealing furnace for annealing treatment. The annealing furnace uses a mesh-belt continuous annealing process with a nitrogen-protected atmosphere (nitrogen purity ≥99.99%) to prevent copper wire oxidation. The annealing temperature is adjusted according to the copper wire diameter: 380℃ for copper wires below 0.5mm, 400℃ for 0.5mm-2.0mm copper wires, and 420℃ for copper wires above 2.0mm. After annealing, the tensile strength of the copper wires decreases to 200MPa-220MPa, and the elongation rate increases to over 30%.

The annealed copper wires are then sent to a bunching machine or stranding machine for processing. For 1mm²-10mm² conductors, a bunching machine is used (bunching speed 6-8r/s) to bundle multiple copper wires into a conductor. For 16mm²-300mm² conductors, a cage stranding machine is employed (stranding speed 3-5r/s) to perform regular stranding. The stranding pitch is controlled to 12-16 times the conductor outer diameter to ensure high conductor roundness (roundness ≥90%). During the stranding process, a tension control system (tension deviation ≤5%) ensures uniform tension of each copper wire, preventing conductor eccentricity.

The manufacturing process of Aluminum Core Conductors is similar to that of copper cores. Aluminum rods (9.5mm in diameter) undergo wire drawing by wire drawing machines (area reduction rate 12%-18%). Due to the relatively low toughness of aluminum wires, the wire drawing speed is controlled at 6-8m/s, lower than that of copper wires. After wire drawing, the aluminum wires are annealed (annealing temperature 350℃-380℃, nitrogen protection) to eliminate internal stress and improve flexibility. The annealed aluminum wires are then stranded into conductors using a stranding machine. During stranding, a small amount of conductive paste is applied between the aluminum wires to reduce contact resistance between strands and prevent local overheating. For 120mm²-300mm² large-specification aluminum core conductors, a split conductor structure is adopted, with each sub-conductor insulated with a thin XLPE layer before stranding, further reducing AC resistance.

Insulation Extrusion Process
For LV PVC-insulated cables, a single-screw extruder (screw length-diameter ratio 25:1) is used for insulation extrusion. The PVC insulation compound (mixed with resin, plasticizers, stabilizers, and flame retardants) is added to the extruder hopper and heated to 160℃-190℃ for melting and plasticization. The melting temperature is controlled in sections: the feeding section is 160℃-170℃, the compression section is 170℃-180℃, and the metering section is 180℃-190℃ to avoid material degradation. The molten PVC material is extruded onto the conductor surface through a crosshead die. The die size is designed according to the conductor specification and insulation thickness, ensuring uniform insulation thickness (deviation ≤±0.1mm). After extrusion, the Insulated Conductor enters a water cooling tank (water temperature 20℃-25℃) for rapid cooling and shaping. The cooling speed is controlled at 3℃/s-5℃/s to prevent insulation layer cracking due to uneven cooling.

For MV XLPE-insulated cables, a three-layer co-extrusion production line is used, which simultaneously extrudes the inner semi-conductive layer, XLPE insulation layer, and outer semi-conductive layer. The inner and outer semi-conductive compounds are made of polyethylene mixed with conductive carbon black (carbon black content 25%-30%), ensuring volume resistivity ≤100Ω·cm. The XLPE insulation compound is composed of HDPE resin, DCP cross-linking agent (content 2%-2.5%), antioxidant, and UV absorber. The extrusion temperature of the three-layer co-extruder is precisely controlled: the inner semi-conductive layer is 180℃-190℃, the XLPE insulation layer is 185℃-195℃, and the outer semi-conductive layer is 180℃-190℃. After extrusion, the insulated conductor enters a vertical cross-linking tube for high-pressure steam cross-linking. The cross-linking temperature is 230℃-250℃, and the pressure is 1.8MPa-2.0MPa. The cross-linking time is adjusted according to the insulation thickness: 15 minutes for 3.4mm (6kV) insulation, 20 minutes for 4.5mm (10kV) insulation, and 30 minutes for 6.0mm (20kV) insulation. After cross-linking, the conductor is cooled by demineralized water to room temperature, and then undergoes a degassing process (heating to 70℃-80℃ for 48 hours) to remove residual cross-linking by-products (such as acetophenone), ensuring stable insulation performance.

Shielding and Armoring Processes
For Mv Cables, a copper Tape Shielding layer is applied after insulation extrusion. The copper tape thickness is 0.15mm-0.2mm, and it is wrapped around the outer semi-conductive layer with an overlap rate of 15%-20% to ensure continuous shielding. For cables with high shielding requirements (such as 20kV cables), a copper wire + copper tape composite shielding structure is used: copper wires (diameter 0.5mm) are spirally wound first (winding density ≥90%), and then copper tape is wrapped outside, effectively reducing electromagnetic interference.

The armoring process is performed according to the product style. For steel tape armoring, a horizontal armoring machine is used. The steel tape (thickness 0.8mm-1.2mm for single-layer, 0.5mm-0.8mm for double-layer) is fed into the machine and spirally wrapped around the cable core. The armoring pitch is controlled to 12-16 times the steel tape width to ensure that the steel tape fits tightly with the cable core. During armoring, a layer of asphalt is coated between the cable core and the steel tape to prevent water intrusion. For wire armoring (used in harsh mining environments), high-carbon steel wires (diameter 2.0mm-2.5mm) are used, and the armoring machine winds the steel wires around the cable core in a double-helix manner, with a tensile strength ≥1500MPa, enhancing the cable's resistance to mechanical impact.

Sheath Extrusion and Quality Inspection Processes
Sheath extrusion is the final step in cable manufacturing. For PVC sheaths, a single-screw extruder (screw length-diameter ratio 28:1) is used, with an extrusion temperature of 165℃-195℃. The PVC sheath compound is added with weather-resistant agents and anti-aging agents to improve outdoor service life. The extruded sheath is cooled by a water tank and then printed with product identification (model, specification, manufacturer, production date) using a laser coding machine. The identification is required to be clear and wear-resistant, with no fading after 100 rubs with a dry cloth. For PE sheaths and rubber sheaths, corresponding extruders and process parameters are used: PE sheaths are extruded at 180℃-210℃, and rubber sheaths are extruded at 90℃-110℃ (using a cold-feed extruder) and then vulcanized in a continuous vulcanization tube (160℃-180℃) to improve elasticity and wear resistance.

Quality inspection runs through the entire production process. Raw material inspection includes testing the chemical composition of copper/aluminum rods, the insulation resistance of PVC/XLPE compounds, and the flame retardancy of sheath materials. Semi-finished product inspection covers conductor resistance (tested by a double-arm bridge), insulation thickness (measured by an ultrasonic thickness gauge), and shielding effectiveness (tested by an electromagnetic interference tester). Finished product inspection includes:

Electrical performance tests: Conductor DC resistance (complying with GB/T 3956-2008), insulation withstand voltage (1.8kV/1min for LV, 2.5×rated voltage/1min for MV), and partial discharge (≤10pC for MV).
Mechanical performance tests: Tensile strength and elongation at break of insulation and sheath (tested by a universal testing machine), and impact resistance (tested by a drop weight impact tester, 10J impact energy with no damage).
Environmental performance tests: Damp heat aging (1000 hours at 40℃, 95% relative humidity, insulation resistance retention ≥80%), UV aging (168 hours of xenon lamp irradiation, no cracking), and oil resistance (soaked in No. 10 machine oil for 72 hours, volume change ≤5%).

Only finished products that pass all inspections are labeled and stored in the warehouse, with each batch accompanied by a quality inspection report for traceability.

II. From the Perspective of Product General Information

(I) Packaging

Standard Packaging Solutions
Cables are packaged based on their specifications and lengths to ensure safety during storage and transportation. For small-specification cables (1mm²-10mm², length 100m-500m), cardboard spools (diameter 300mm-500mm) are used. The cable is neatly wound on the spool, and the surface is wrapped with two layers of waterproof kraft paper. Each spool is placed in a corrugated carton (five-layer, compressive strength ≥1500N/m²), with bubble film filled in the gaps to prevent movement.

For medium-specification cables (16mm²-70mm², length 200m-1000m), wooden cable drums (diameter 800mm-1200mm) are adopted. The drum body is made of poplar plywood (18mm thick), reinforced with galvanized steel strips (30mm wide) at the edges to prevent deformation. The cable is wound with a constant tension (300N-500N) to avoid loosening. The drum surface is covered with a plastic film to protect against moisture, and a label is affixed, indicating the cable model, specification, length, batch number, and production date.

For large-specification cables (120mm²-300mm², length 50m-500m), steel cable drums (diameter 1500mm-2000mm) are used. The drum is made of 3mm-5mm cold-rolled steel plates, with an anti-rust coating (zinc plating thickness ≥80μm) on the surface. The cable is wound with a tension of 600N-800N, and a layer of foam rubber (5mm thick) is laid between the cable and the drum to prevent sheath scratches. Steel drums are suitable for sea transportation and long-term outdoor storage, with a load-bearing capacity ≥500kg.

Customized Packaging Services
For export customers, packaging complies with ISPM 15 standards. Wooden drums undergo heat treatment (56℃ for 30 minutes) or fumigation (methyl bromide) to eliminate pests, and are marked with the ISPM 15 logo. For customers in cold regions, the cable surface is coated with anti-freeze oil (operating temperature -40℃ to 60℃) before packaging, and the drum is wrapped with thermal insulation cotton to prevent insulation cracking due to low temperatures.

For customers requiring on-site construction convenience, "pay-off drum" packaging is provided. The drum is equipped with a built-in bearing, allowing easy rotation during cable unwinding, reducing labor intensity. For large-scale project orders (≥10,000m), containerized packaging is used: multiple steel drums are placed in a 40-foot container, with wooden blocks fixed to prevent collision, and the container is equipped with a moisture absorber to control humidity ≤60%.

(II) Transportation

Transportation Mode Selection
Road transportation is preferred for short-distance (≤500km) and small-batch (≤500m) orders. Medium-duty trucks (load capacity 10-20 tons) with a flatbed or closed carriage are used. The carriage is lined with rubber pads to reduce vibration. For large-specification steel drums, a crane is used for loading and unloading, with a maximum loading capacity of 8-10 drums per truck. Road transportation offers flexibility, with door-to-door delivery within 1-3 days, suitable for emergency maintenance projects.

Railway transportation is used for long-distance (≥1000km) and large-batch (≥1000m) orders. Gondola cars or covered cars are selected, with a single car capable of loading 20-30 wooden/steel drums. The drums are fixed with steel wires and wooden wedges to prevent sliding during transportation. Railway transportation has low costs (20%-30% lower than road) and stable schedules, with a transit time of 3-7 days for major industrial zones.

Sea transportation is the main mode for export orders. 20-foot containers can hold 8-12 steel drums (120mm²-300mm²), and 40-foot containers can hold 15-25 drums. The containers are checked for water tightness before loading, and the drums are secured with container twist locks. For sensitive regions (such as high-humidity areas), desiccant bags (500g each) are placed in the container to absorb moisture. Sea transportation takes 15-30 days for Southeast Asia, 30-45 days for Europe, and 45-60 days for North America, with costs 50%-70% lower than air transportation.

Air transportation is reserved for urgent orders (such as emergency cable replacement for power outages). The cable is packaged in lightweight cartons (gross weight ≤30kg per carton) and transported via cargo airlines. The transit time is 3-7 days globally, but costs are 8-10 times higher than sea transportation, making it suitable for small-batch (≤100m) urgent needs.

Loading, Unloading, and Transportation Protection
Loading and unloading operations are performed by professional teams using cranes or forklifts with soft lifting slings (to avoid damaging the drum surface). For wooden drums, the lifting point is at the drum's central axis; for steel drums, a dedicated lifting bracket is used to prevent drum deformation. The loading sequence follows "heavy at the bottom, light at the top" to ensure vehicle stability. The gap between drums is filled with foam boards to prevent collision during transportation.

During transportation, temperature and humidity monitoring devices are placed in the carriage/container to track environmental conditions (temperature -30℃ to 60℃, humidity 30%-80%). For road transportation, GPS positioning is used to monitor the vehicle's location and speed (highway speed ≤80km/h, national road ≤60km/h). For sea transportation, the shipping company provides real-time navigation updates, and the factory coordinates with the destination port to arrange customs clearance in advance.

In case of unexpected events (such as traffic accidents, port delays), the factory activates an emergency plan: for damaged cables, a replacement batch is produced within 24-48 hours; for delayed shipments, alternative transportation modes (such as switching from sea to air) are arranged to minimize impact on the customer's project schedule.

(III) Shipping

Order Confirmation and Production Scheduling
After receiving the customer's order, the sales team confirms details (model, specification, quantity, delivery time,

destination) via a written contract. The contract clearly defines quality standards, payment terms, and liability for breach, and takes effect after both parties sign and seal it. The sales department then converts the order into a production task list and submits it to the production planning department. The production planning department formulates a detailed production schedule based on the factory's equipment capacity, raw material inventory, and customer delivery requirements. For example, for an order of 5000m 120mm² MV XLPE copper-core cables with a 15-day delivery period, the schedule allocates 3 days for conductor manufacturing, 4 days for insulation extrusion and cross-linking, 2 days for shielding and armoring, 2 days for sheath extrusion, 2 days for quality inspection, and 2 days for packaging and shipping, with 1 day reserved as a buffer for unexpected delays.

The production planning department also coordinates with the purchasing department to ensure raw material supply. For instance, if the order requires high-purity electrolytic copper rods, the purchasing department verifies the inventory first; if stock is insufficient, it places an urgent order with designated suppliers and tracks the logistics progress to ensure the copper rods arrive at the factory within 3 days. For special materials such as flame-retardant rubber sheaths, the purchasing department confirms the production cycle with suppliers in advance to avoid production interruptions.

Pre-Shipment Inspection and Document Preparation

Before shipment, the quality control department conducts a 100% pre-shipment inspection of the finished cables. For electrical performance, it randomly samples 5% of each batch to test conductor DC resistance (e.g., 120mm² copper-core conductor resistance ≤0.153Ω/km), insulation withstand voltage (10kv Cables undergo 25kV/1min test with no breakdown), and partial discharge (≤10pC at 17.3kV). For mechanical performance, it checks the tensile strength of the sheath (PVC sheath ≥12MPa) and impact resistance (10J drop weight impact with no sheath cracking). For appearance, it inspects the cable surface for scratches, bubbles, or uneven thickness, ensuring the outer diameter deviation is within ±0.5mm.

Simultaneously, the logistics department prepares complete shipping documents. For domestic shipments, the documents include a commercial invoice (detailing product name, specification, quantity, unit price, and total amount), a packing list (indicating package number, gross weight, net weight, and cable length per package), and a quality certificate (signed by the quality control director, certifying compliance with GB/T 12706 standards). For export shipments, additional documents are required: a customs declaration form (filled in accordance with the destination country's customs regulations), a certificate of origin (issued by the local entry-exit inspection and quarantine bureau), and an ISPM 15 phytosanitary certificate (for wooden drum packaging). All documents are provided in both Chinese and English, with consistent information to avoid customs clearance delays.

Shipment Coordination and Notification

After passing the pre-shipment inspection and completing document preparation, the logistics department arranges shipment based on the agreed transportation mode. For road transportation, it dispatches trucks with GPS tracking and coordinates with the driver to arrive at the factory at 8:00 a.m. on the scheduled loading date. The loading process is supervised by quality control personnel to ensure the cables are placed vertically (for drums) and secured with steel wires to prevent sliding. For railway transportation, the logistics department delivers the cable drums to the designated railway station 2 days in advance, coordinates with the station to allocate a freight car, and completes the loading and waybill formalities. For sea transportation, it delivers the containers to the port 5 days before the ship's departure, completes customs declaration, and provides the customer with the bill of lading number 3 days in advance, allowing the customer to track the shipment online.

The sales team notifies the customer of the shipment details via email or SMS 24 hours before shipment, including the transportation mode, vehicle/ship number, estimated arrival time, and contact information of the logistics coordinator. For example, if the cables are shipped to a machinery factory in Guangzhou via road, the customer receives a message stating: "Your order (No. XC20240512) has been shipped via truck (License Plate: Guang A12345), estimated arrival time: May 18, logistics coordinator: Li Ming, Phone: 138xxxx5678." During transportation, the sales team updates the customer on the progress every 48 hours until the cables arrive.

(IV) Samples
Sample Customization and Production
The factory provides free sample services for potential customers to verify product performance. When a customer requests a sample (e.g., 10m 25mm² LV PVC aluminum-core cable for a chemical plant), the sales engineer first confirms details such as conductor material, insulation type, sheath color (customizable to RAL 7035 gray), and special requirements (e.g., oil resistance). The sales engineer then issues a "sample production order" and sends it to the technical department, which designs the production process—for example, adjusting the aluminum wire stranding pitch to 10 times the outer diameter to enhance flexibility.
The sample production is assigned to a dedicated workshop with advanced equipment. For the 25mm² aluminum-core conductor, the workshop uses 96 strands of 0.58mm aluminum wires, stranded at 6r/s with uniform tension. The PVC insulation extrusion uses a small single-screw extruder, with the temperature controlled at 170℃-180℃ to ensure a smooth insulation surface. The sample is produced within 3 days and then sent to the quality control department for testing, including insulation thickness (0.9mm) and oil resistance (soaked in No. 10 machine oil for 24 hours with no volume expansion exceeding 5%).
Sample Delivery and Follow-Up
Qualified samples are packaged in moisture-proof plastic bags and placed in hard cartons with foam padding to prevent damage during transportation. For domestic customers, the factory uses SF Express for delivery, ensuring arrival within 2-3 days; for international customers, it uses DHL, with a delivery time of 5-7 days. The sample package includes a sample label (indicating model, specification, and production date) and a product brochure (introducing technical parameters and application cases).
The sales engineer follows up with the customer 3 days after sample delivery to inquire about test progress. If the customer is satisfied with the sample (e.g., the oil resistance meets the chemical plant's requirements), the sales engineer provides a detailed quotation for the formal order and introduces preferential policies such as a 2% discount for orders over 10,000m. If the customer has concerns (e.g., the sample's flexibility is insufficient), the sales engineer forwards the feedback to the technical department, which adjusts the process (e.g., reducing the aluminum wire stranding pitch to 8 times the outer diameter) and re-produces the sample within 2 days. The re-produced sample is sent to the customer with a test report comparing the performance before and after adjustment.
(V) After-Sales Service
Installation Guidance and Technical Support
The factory offers comprehensive installation guidance to ensure correct cable use. Before installation, the after-sales department sends a digital version of the "Cable Installation Manual" to the customer, which includes 3D diagrams of common installation scenarios (e.g., overhead erection, underground burial) and step-by-step instructions: for underground burial of 120mm² MV cables, the manual specifies a burial depth of ≥0.7m, sand cushioning (thickness ≥100mm) around the cable, and warning tape laid 300mm above the cable. The manual also includes a troubleshooting section, such as solutions for insulation resistance drop (e.g., cleaning the cable surface with alcohol).
For large-scale projects (e.g., a 50,000m cable laying project for a metallurgical plant), the factory dispatches 2 senior after-sales engineers to the site 1 week before installation. The engineers inspect the installation environment first—for example, checking if the cable trench has sharp rocks (which need to be removed) or if the overhead poles have sufficient load-bearing capacity. During installation, they guide the construction team on cable unwinding speed (≤5m/min to avoid conductor damage) and terminal crimping (using a 12-ton crimping tool for 120mm² conductors). They also conduct on-site training for the customer's maintenance personnel, covering daily inspection items (e.g., checking cable temperature with an infrared thermometer) and emergency handling (e.g., cutting off power immediately if the cable surface temperature exceeds 90℃).
Quality Complaint Handling
The factory adheres to a "24-hour response" principle for quality complaints. If a customer reports a problem (e.g., a 70mm² cable sheath cracking after 1 month of use in a workshop), the after-sales department records the details (order number, installation date, and problem description) and assigns an engineer to investigate within 2 hours. The engineer first analyzes the quality inspection records of the batch to check if the sheath material meets standards; if necessary, they visit the site to collect a sample for testing (e.g., testing the sheath's tensile strength and elongation at break).
If the problem is caused by product quality (e.g., the sheath material has insufficient plasticizer), the factory offers three solutions: free replacement of the defective cable (delivered within 3 days), on-site repair (e.g., wrapping the cracked area with heat-shrinkable sleeves), or partial compensation (based on the defective length). For example, if 50m of cable is defective, the factory replaces 50m of new cable and bears the transportation cost. If the problem is caused by improper installation (e.g., the cable was bent beyond the minimum bending radius), the after-sales engineer provides correct installation guidance and helps the customer repair the cable if possible. After resolving the issue, the factory conducts a follow-up after 1 month to confirm the cable operates normally and updates the "quality complaint database" to prevent similar problems.
Spare Parts Supply and Maintenance Services
The factory maintains a spare parts warehouse in major industrial hubs (e.g., Shanghai, Guangzhou, Wuhan) stocked with common spare parts such as cable terminals (copper-aluminum transition terminals for 10mm²-300mm² cables), insulation sleeves (heat-shrinkable sleeves resistant to 125℃), and armor repair kits (including steel tape and asphalt). Customers can place orders for spare parts via the official website or after-sales hotline, with domestic delivery within 24 hours. For example, if a power plant in Wuhan needs 100 copper terminals for 240mm² cables, the warehouse dispatches them via SF Express, ensuring arrival the next day.
For long-term cooperative customers (e.g., annual purchases over 1 million yuan), the factory provides annual free maintenance services. In spring and autumn each year, after-sales engineers visit the customer's site to inspect the cables: they measure the insulation resistance of MV cables (using a 2500V insulation resistance tester, requiring ≥1000MΩ), check the armor layer for rust (touching up with anti-rust paint if rust is found), and clean the cable surface (using a non-corrosive cleaning agent). After the inspection, they issue a maintenance report with recommendations—for example, suggesting the customer replace the 10-year-old 6kV cables in the workshop to avoid insulation aging.
Emergency Support
The factory has an emergency support team available 24/7 to handle urgent situations such as power outages caused by cable faults. If a customer (e.g., a food processing plant) reports a cable breakdown at 2:00 a.m., the after-sales hotline connects to the on-duty engineer immediately. The engineer first asks for details (e.g., cable model, fault location, and whether there is smoke or sparks) to preliminary judge the cause, then dispatches an emergency team with repair equipment (cable fault locator, crimping tool) and spare cables to the site.
For example, if the fault is a broken 120mm² MV cable in the plant's main power line, the emergency team arrives within 3 hours, uses the fault locator to find the break point within 30 minutes, cuts off the defective section, and splices the cable with a waterproof joint. The entire repair process takes about 2 hours, restoring power supply for the customer as soon as possible. After the emergency is resolved, the team submits a fault analysis report to the customer, explaining the cause (e.g., rodent damage) and proposing preventive measures (e.g., installing rodent repellents around the cable trench).
In summary, the LV PVC and MV XLPE Insulated copper/aluminum core Industrial Cables (1-300mm² custom sizes) integrate high performance, diverse customization, and thoughtful services. From product design and production to packaging, transportation, sampling, and after-sales support, the factory adheres to the concept of "customer-centricity" to provide a one-stop solution. Whether in the high-temperature, high-dust environment of a metallurgical plant, the corrosive atmosphere of a chemical workshop, or the long-distance power transmission scenario of an industrial park, these cables deliver stable and reliable performance, while the comprehensive after-sales system further ensures the smooth operation of the customer's power supply network, creating long-term value for industrial production.