The Artisanal Birth of an Industrial Cable

1. Raw Material Inspection: The First Line of Quality Control

• Copper Material Testing: Laboratory technicians use spectrum analyzers and resistance testers to inspect the purity and conductivity of copper batches, ensuring resistance values meet national standards and eliminating impurities that could affect electrical performance.

• Plastic Material Inspection: Insulation and sheathing compounds undergo tensile, temperature resistance, and oil resistance tests. Only materials that meet UL and CE environmental standards are labeled as qualified.

• Intelligent Warehousing: Qualified raw materials are scanned via RFID and logged into the MES system, automatically assigned to storage locations, and linked to batches, enabling full traceability from warehousing to usage.

2. Wire Drawing & Stranding: Forging the "Backbone" of the Cable

• Precision Control: Drawing tension and stranding pitch are automatically regulated by PLC systems, with errors controlled at the micron level to ensure uniform conductor structure and flexibility.

• Flexible Craftsmanship: For high-flex drag chain cables and robot cables, an ultra-fine multi-strand tinned copper wire structure is adopted, allowing the cables to withstand millions of bends without breaking.

• Real-Time Monitoring: Workshop displays show real-time data on wire diameter, speed, and temperature, with automatic early warnings for abnormalities to eliminate semi-finished product defects.

3. Insulation Extrusion & Shield Braiding: The "Protective Armor" for Signal Transmission

• High-Precision Temperature Control: Extrusion temperature is stabilized at 180-200°C, ensuring the insulation layer is free of bubbles, scratches, and has strong adhesion.

• Tight Shield Fit: Braiding machines operate at hundreds of revolutions per minute, with copper mesh tightly wrapping the core to build an "electromagnetic firewall" for signal transmission.

• Online Inspection: Spark testers conduct real-time voltage resistance tests, with every meter of cable subjected to 3-5kV high-voltage testing to ensure no insulation breakdown.

4. Cabling & Sheathing: Giving the Cable Its Complete "Life Form"

• Weather-Resistant Formula: The sheathing material uses special modified compounds, enabling stable operation in -40°C to 105°C environments, with oil resistance, acid and alkali resistance, and aging resistance.

• Clear Marking: Cable surfaces are laser-printed with specifications, models, certifications, and length markers, ensuring clear, wear-resistant text for easy construction and maintenance.

• Intelligent Winding: Automatic length counting and tension control ensure neat coiling, with 1.5m test sections reserved at both ends of each coil.

5. Full-Spectrum Quality Inspection: Leaving No Room for Defects

• Electrical Performance Testing: Conductor resistance, insulation resistance, voltage resistance, and partial discharge tests ensure electrical performance meets standards.

• Mechanical Performance Testing: Tensile, bending, and torsion tests—drag chain cables withstand 15 million bends, and robot cables withstand ±180° torsion cycles 100,000 times.

• Environmental Simulation Testing: Temperature, oil, weather, and flame retardant tests simulate extreme working conditions to verify stability.

• Appearance & Dimension Inspection: Projectors measure structural dimensions to ensure outer diameter, thickness, and structure fully comply with standards.

6. Intelligent Management: Digitalization Empowers Efficient Production

• Intelligent Production Scheduling: Automatically matches orders, equipment, and materials, flexibly handling urgent orders with an on-time delivery rate exceeding 98%.

• Full Traceability: One product, one code—scanning reveals raw material batches, equipment parameters, operators, and inspection records.

• Digital Dashboard: Real-time display of output, progress, pass rate, and equipment status for transparent, controllable production.

• Lean Production: Implements 6S management, pre-shift safety meetings, and regular equipment maintenance to ensure safety and efficiency.

7. Artisanal Persistence: Connecting the World, Creating with Joy

• 24-Hour Operation: Equipment runs an average of 22 hours per day, producing over 5 million kilometers of various cables annually.

• Artisanal Team: A technical and operational team with an average of 8+ years of industry experience controls every detail with expertise and data.

• Mission-Driven: Guided by the philosophy of "Integrity First, Quality Excellence, Service Supreme", Tongle Cable provides the "industrial nerves" for intelligent manufacturing, robotics, new energy, and automated production lines.