Aluminum Melting and Casting: High-purity aluminum ingots are melted in a gas-fired furnace at 700–750℃. The molten aluminum is refined to remove impurities (e.g., oxides, metals) and cast into cylindrical billets (diameter: 80mm–120mm) using a continuous casting machine.
Wire Drawing: The billets are extruded into aluminum rods (diameter: 9.5mm) and then drawn through diamond dies of decreasing diameters to form strands of the required thickness (0.5mm–2.5mm). The drawing process is lubricated with mineral oil to reduce friction and prevent surface damage.
Annealing: The drawn strands undergo annealing in a continuous furnace at 350–400℃ to soften the metal, improving flexibility and relieving internal stress from drawing.
Stranding: The annealed strands are twisted into concentric layers using a stranding machine, with a lay length (distance of one full twist) of 10–20 times the strand diameter to ensure mechanical stability.
Alloy Melting and Casting: Aluminum ingots are melted with precise amounts of magnesium and silicon (per AAAC alloy specifications) in a controlled-temperature furnace (720–760℃). The molten alloy is cast into billets using the same continuous casting process as AAC.
Wire Drawing and Annealing: The alloy billets are extruded into rods and drawn into strands, with annealing temperatures adjusted to 380–420℃ to optimize the alloy’s mechanical properties.
Stranding: The alloyed strands are twisted into conductors using the same stranding process as AAC, ensuring uniform structure and conductivity.
Material Preparation: XLPE compound (HDPE resin + cross-linking agents + additives) is mixed in a high-speed mixer (1000–1500 rpm) at 80–100℃ to ensure uniform dispersion of additives. The mixed compound is pelletized for easy feeding into the extruder.
Extrusion: The XLPE pellets are fed into a single-screw extruder with a temperature-controlled barrel (120–160℃). The pellets melt and homogenize in the extruder, then are forced through a crosshead die. The aluminum conductor (AAC or AAAC) is pulled through the center of the die, and the molten XLPE adheres to its surface, forming a uniform insulation layer. The die size is calibrated to achieve the specified insulation thickness (±0.1mm tolerance).
Cross-Linking: The insulated conductor passes through a continuous vulcanization (CV) tube, where it is heated to 180–200℃ using steam or hot air. This activates the cross-linking agent, transforming the XLPE into a thermoset material with enhanced thermal and mechanical properties. The CV tube length (10–20 meters) is adjusted to ensure complete cross-linking.
Cooling: The cross-linked insulated conductor is cooled in a water bath (20–30℃) to solidify the insulation and prevent thermal deformation. The cooling rate is controlled to avoid internal stress in the XLPE layer.
Conductor Alignment: Four insulated conductors (3 phase + 1 neutral) are fed into a bundling machine, where they are aligned in a compact, parallel configuration. The spacing between conductors is set to 2–3mm to ensure uniform bundling and prevent contact between insulation layers.
Binding: A polyester tape is wrapped around the aligned conductors using a tape-laying machine, with a 50% overlap to ensure full coverage. The tape tension is controlled to avoid damaging the insulation while maintaining bundle integrity.
Outer Sheathing (Optional): For cables requiring extra protection (e.g., industrial or coastal applications), a PE outer sheath is extruded over the bundled conductors using a second extruder (barrel temperature: 130–150℃). The sheath thickness is monitored via laser gauges to maintain the specified tolerance (±0.1mm).
Terminal Processing: The bundled cable is cut to standard lengths (e.g., 10m, 20m, 50m) using a precision cutting machine. Copper-aluminum transition terminals are crimped to both ends of the cable using a hydraulic crimping machine, with crimping pressure controlled (20–30kN) to ensure a secure, low-resistance connection. The terminals are then inspected for crimp quality and coated with anti-corrosion grease.
Raw Material Testing: Aluminum purity (via optical emission spectrometry), XLPE dielectric strength (via breakdown voltage test), and polyester tape tensile strength (via universal testing machine) are verified upon receipt.
In-Process Inspection: Conductor diameter (via micrometer), insulation thickness (via laser gauge), bundle alignment (via visual inspection), and terminal crimp quality (via cross-sectional analysis) are checked at 10-minute intervals.
Finished Product Testing:
Electrical Tests: Insulation resistance (megohmmeter), voltage withstand (1.5× rated voltage for 1 minute), and conductor continuity (to ensure no breaks in strands).
Mechanical Tests: Tensile strength of conductors (universal testing machine), bending resistance (mandrel bending test), and terminal pull-out force (to verify crimp strength).
Environmental Tests: UV resistance (accelerated aging chamber), thermal cycling (-40℃ to 90℃, 100 cycles), and salt spray resistance (for AAAC conductors, 500 hours of salt spray exposure).
Service Drop-Specific Tests: Bending fatigue (1000 cycles of bending to minimum radius), terminal connection resistance (via micro-ohmmeter), and weather resistance (simulating 5000 hours of outdoor exposure).
Reel Materials: Two types of reels are used:
Wooden Reels: For AAC Cables and short-length AAAC Cables (≤200m). Constructed from high-density plywood (thickness 15–20mm) treated with anti-corrosion and moisture-resistant coatings (polyurethane). Reels feature a central core (diameter 150–200mm) and flanges (diameter 600–800mm) reinforced with steel rings to prevent cracking.
Steel Reels: For long-length AAAC cables (>200m) or heavy-duty shipping. Made of galvanized steel (thickness 3–5mm) for durability, with a central hub (diameter 200–300mm) and lifting lugs for crane handling.
Cable Winding: The bundled cable is wound onto the reel using a reeling machine with controlled tension (50–80N) to ensure uniform winding and avoid kinking. A layer of kraft paper is placed between cable layers to prevent insulation abrasion.
Protective Layers: After winding, the cable is wrapped with a transparent PE film (thickness 0.05mm) to shield against dust and moisture. For outdoor storage or sea freight, an additional hessian cloth (weight 200g/m²) is wrapped around the PE film to provide mechanical protection.
Labeling: Each reel is labeled with a weather-resistant sticker containing: product type (Quadruplex Service Drop Cable), specifications (0.6/1kV, conductor type, cross-sectional area, length), batch number, manufacturing date, compliance certifications (IEC, GB), and handling instructions (“Keep Dry,” “Do Not Stack Above 2 Layers,” “Use Crane for Lifting”).
Wooden reels and pallets are sourced from FSC-certified forests, ensuring responsible forestry.
Cardboard boxes, kraft paper, and PE film are fully recyclable.
Steel reels are reusable; the manufacturer offers a take-back program for customers to return used reels for refurbishment.
Road Transport: For small to medium shipments (1–2 reels or boxed custom lengths), enclosed trucks are used to protect against weather (rain, snow, extreme temperatures) and road debris. Reels are secured with steel straps and wooden blocks; boxed cables are stacked on pallets and secured with load locks. For oversized steel reels, flatbed trucks with weather-resistant tarpaulins are used.
Rail Transport: For large domestic shipments (5+ reels or full pallets), rail transport is cost-effective for long distances. Reels are loaded into enclosed railcars and secured with blocking. Local trucking companies handle last-mile delivery to the customer’s site.
Sea Freight: For bulk international shipments (full container loads), 20-foot or 40-foot shipping containers are used. Reels are secured with blocking and bracing to prevent movement during the voyage. Desiccant packs (500g each) are placed inside containers to absorb humidity, protecting against saltwater spray. Transit times range from 2–8 weeks, depending on the destination.
Air Freight: For urgent shipments (small custom lengths or samples), air freight is used. Cables are packaged in lightweight boxes to minimize weight and volume. Air cargo containers withstand pressure and temperature changes during flight, with transit times of 1–5 days.
Handling Guidelines: All packages are labeled with clear instructions (e.g., “Maximum Stack Height: 2,” “Lift at Hub Only”). Logistics partners receive a handling manual outlining proper loading/unloading procedures to avoid insulation damage.
Temperature Control: For shipments to extreme climates (temperatures < -20℃ or > 45℃), temperature-controlled vehicles or containers maintain a 0℃–40℃ range, preventing insulation brittleness or softening.
Moisture Control: Sea freight shipments include vapor barrier film and extra desiccant packs to prevent moisture ingress.
Regulatory Compliance: The cable is classified as non-hazardous, but complies with transportation regulations (IMDG Code for sea freight, IATA for air freight). Packaging meets ISTA 3A standards for transit durability.
Documentation: Each shipment includes a commercial invoice, packing list, bill of lading/air waybill, certificate of origin, and compliance certificates. For international shipments, customs documents are prepared with a licensed broker to ensure smooth clearance.
The recipient inspects the packages for damage (e.g., cracked reel flanges, torn PE film, crushed boxes) and verifies the number of packages against the shipping manifest.
Any damage is documented with photographs, and the recipient notifies the manufacturer within 48 hours of delivery.
The recipient signs a delivery confirmation form, which is shared with the manufacturer to confirm successful delivery.
The shipment was received in the expected condition.
The product specifications match the order requirements.
The customer has no immediate concerns about the cable’s quality or packaging.
Direct Contact: Via phone or email with the manufacturer’s sales team, providing details such as conductor type (AAC/AAAC), cross-sectional area, length (typically 1–5 meters), and intended application (e.g., residential service drop, commercial branch connection).
Online Portal: Through the manufacturer’s official website, using a dedicated sample request form that collects the customer’s contact information (name, company, email, phone), project details, and sample specifications.
Authorized Distributors: Via local distributors, who forward the request to the manufacturer for processing, ensuring regional accessibility and timely support.
Material Selection: The same AAC/AAAC conductors and XLPE insulation used in full production are selected for samples, ensuring the sample’s performance matches the final product.
Processing: The cable is cut to the requested length using a precision cutting machine, ensuring clean, straight cuts that do not damage the XLPE insulation or conductors. For samples with pre-processed terminals, the terminals are crimped using automated equipment to ensure consistent connection quality.
Testing: Each sample undergoes a series of quality checks:
Visual Inspection: Checking for insulation uniformity (no cracks, bubbles, or surface defects), conductor alignment in the bundled structure, and clear marking of specifications (voltage rating, conductor type).
Electrical Test: Measuring insulation resistance with a megohmmeter to ensure it meets the minimum standard of >1000MΩ·km.
Mechanical Test: Bending the sample around a mandrel (15× the cable’s overall diameter) to confirm flexibility and check for insulation cracking.
1–2 Meter Samples: Coiled and placed in a rigid cardboard tube (diameter 50mm) with foam plugs at both ends to avoid bending or crushing.
3–5 Meter Samples: Wound onto a small plastic reel (diameter 100mm) and wrapped in clear PE film to protect against dust and moisture.
A label with the sample specifications (conductor type, cross-sectional area, length), batch number, and manufacturing date.
A one-page product datasheet summarizing key performance parameters (current-carrying capacity, temperature range, insulation resistance).
A cover letter from the sales team, offering assistance with any questions or further testing needs (e.g., requesting additional mechanical or environmental tests).
The customer’s impression of the sample’s quality (e.g., insulation smoothness, terminal connection firmness).
Performance in preliminary tests (e.g., compatibility with installation tools, resistance to bending).
Suitability for the customer’s project (e.g., whether the conductor’s current-carrying capacity meets their load requirements).
Hotline: A toll-free number staffed by engineers with expertise in low-voltage terminal service drop systems, providing real-time assistance for critical issues.
Email: A dedicated technical support email address with a 24-hour response time for urgent queries and a 48-hour response time for general questions.
Online Portal: A password-protected portal featuring resources such as installation guides, video tutorials, and a FAQ section addressing common issues (e.g., “How to install pre-processed terminals?” “What is the maximum service drop span?”).
On-site Support: For complex issues (e.g., large-scale installation errors, widespread insulation failure), the manufacturer dispatches a technical representative to the customer’s site within 48 hours (domestic) or 72 hours (international).
Installation Guidance: Providing step-by-step instructions for reel unwinding (to avoid kinking), proper tensioning (to prevent conductor damage), and terminal connection (ensuring compatibility with meters or distribution boxes). For special scenarios (e.g., service drops across narrow alleys or sloped terrain), the team develops customized installation plans.
Troubleshooting: Guiding customers through diagnostic steps for issues such as insulation breakdown (using a megohmmeter to measure resistance), terminal overheating (checking connection tightness), or conductor damage (inspecting for kinks or breaks). The team may request photos or videos of the issue to provide targeted solutions.
Compatibility Checks: Verifying compatibility with existing infrastructure (e.g., meters, distribution boxes, service drop brackets) to avoid installation errors. If incompatibilities are identified, the team recommends alternative hardware or modifications.
AAC Cables: 15-year warranty, covering defects in materials and workmanship.
AAAC Cables: 20-year warranty, extending coverage due to the enhanced corrosion resistance and mechanical strength of alloyed aluminum.
Insulation breakdown (when operated within the 0.6/1kV rated voltage range).
Conductor strand breakage (not caused by improper tension or external damage).
Failure of pre-processed terminals (e.g., loosening or corrosion due to manufacturing defects).
Degradation of the bundled structure (e.g., conductor separation due to defective binding).
Improper installation (e.g., bending below the minimum radius, over-tensioning, incorrect terminal connection).
Misuse (e.g., operating above the rated voltage or temperature, exposing the cable to industrial chemicals).
External factors (e.g., lightning strikes, severe storms, vandalism, or animal damage).
Normal wear and tear (e.g., minor surface scratches on insulation that do not affect performance).
A completed warranty claim form (available on the manufacturer’s website), including the order number, product specifications, and a detailed description of the issue.
Proof of purchase (invoice or delivery receipt) to verify the purchase date and ownership.
Photographs or videos of the defect, clearly showing the issue and the cable’s batch number (printed on the insulation).
A brief report outlining the operating conditions (e.g., temperature range, load capacity, installation environment) and any troubleshooting steps taken.
Replacement: Shipping a new cable of the same specifications, with the manufacturer covering all shipping costs.
Repair: Dispatching a technical team to repair the defect on-site (e.g., replacing a damaged section of cable or re-crimping terminals) for large-scale installations.
Pro-rated Refund: Providing a partial refund based on the remaining warranty period if the defect affects only a portion of the cable.
Mild Environments (e.g., suburban residential areas): Visual inspections every 12 months.
Harsh Environments (e.g., coastal areas, industrial zones): Visual inspections every 6 months, plus annual electrical testing.
Insulation Condition: Checking for cracks, fading, swelling, or UV damage (e.g., chalky surface). For coastal areas, inspecting for saltwater-induced corrosion on terminals.
Conductor and Terminal Integrity: Verifying terminals are tight and free of corrosion, and conductors are not exposed or damaged.
Bundled Structure: Ensuring the binding tape or outer sheath remains intact, with no conductor separation.
Insulation Resistance Test: Using a megohmmeter to measure resistance, ensuring it remains above 1000MΩ·km.
Terminal Connection Test: Checking terminal tightness and measuring contact resistance to avoid overheating.
Cleaning: Annual cleaning with a soft, dry cloth to remove dust, dirt, or salt deposits. For stubborn debris, a slightly damp cloth (with water only) is allowed, followed by thorough drying.
Environmental Protection: For high-wind areas, recommending wind deflectors to reduce vibration-induced wear. For cold climates, advising against sharp bending in temperatures below -20℃.
Incorrect/Defective Products: Customers may request a return within 30 days of delivery (domestic) or 60 days (international) if the product does not match the order or is damaged during shipping.
Excess Inventory: Unused, unopened products may be returned within 90 days of delivery, subject to a restocking fee.
The customer requests an RA number via the online portal or email, providing the order number, product details, and reason for return.
The after-sales team reviews the request within 2 business days and issues an RA number if approved, along with return shipping instructions.
For incorrect/defective products, the manufacturer covers return shipping costs and provides a prepaid label.
For excess inventory, the customer is responsible for return shipping.
Hongtai Cable Technology Co. , Ltd
อีเมล: export@qlcables.com
sales@qlcables.com
โทร/whatsapp:+86-18032066271
เพิ่ม： เขตพัฒนาอุตสาหกรรม Xiaokou, Ningjin County, Xingtai City， Hebei Province, จีน
ลิขสิทธิ์© Hongtai Cable Technology Co. , Ltd การสนับสนุนด้านเทคนิค:เทคโนโลยี Ronglida
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