Looking to reduce copper loss, extend tool life, and improve cable quality? This article explores how Nano Compacting Dies delivers measurable results in real-world cable production.
The manufacturing features of the nano compacting dies are:
- With nano-diamond coating
- Hole shape optimization
- Computer-aided inspection
Therefore, the application characteristics of the Nano-diamond Compacting dies are:
(1) Reference life of the dies: 500 to 1,000 kilometers of continuous stranding of the conductor (because of the nano-diamond coating and optimization of the hole pattern)
The working life of the original tungsten carbide dies is only 20 to 30 km.
(2) Hole diameter change when the die is scrapped: 0.00 mm, no need to repair the die (because of the nano-diamond coating)
The original tungsten carbide compacting dies gradually deteriorate in use in terms of finish, and have to be polished many times, the aperture is enlarged accordingly, and the aperture is scrapped when it is super poor.
3）High and constant work surface finish (because of nano-diamond coating)
The original tungsten carbide compacting dies gradually deteriorates in use, and has to be polished many times.
- High dimensional accuracy (because of computer-aided inspection)
Therefore, the direct benefits of Nano Compacting Dies for users are as follows:
1) Improvement of production efficiency (because of the long life and constant hole diameter)
The use of a nano-diamond coating compacting die, in its full life cycle can significantly increase the output, reduce the number of downtime testing, mould change, monofilament breakage rate decreased significantly, reduce the labor intensity of workers, production efficiency increased significantly, can be applied for the enterprise every year to bring a lot of economic benefits.
2) Improvement of the voltage resistance level of the cable (because the aperture remains unchanged)
The stability of the cable cross-section is very good, and the conductor cross-section of the long distance remains unchanged, which is conducive to the semiconductor shielding layer and the thickness of the insulation layer of the stable control, to improve the level of pressure resistance of the cable is also a great benefit.
(3) Saving copper (aluminium), semiconductor materials, and insulation materials (because of the constant aperture diameter)
Due to the aperture being unchanged, compared with the traditional dies it is constantly expanding the aperture, stranding the same length of the cable, you can save 1% to 2% of the weight of the metal material; and the stability of the dies aperture brings about the stability of the cable tightening coefficient, but also save semiconductor materials and insulating materials.
(4) Significantly improve the partial discharge performance of the cable (because of the high work surface finish)
Significantly improve the round conductor surface finish and precision, smooth surface, good brightness, the degree of copper oxidation is reduced, the product outer diameter is uniform, conducive to the stability of the wire core resistance, the wire core surface presents a mirror-like brightness, eliminating the cable conductor surface of the burr and the sharp corners, which can improve the uniformity of the cable in the future operation of the electric field distribution, and is conducive to improving the insulation level of the cable ( Especially the level of partial discharge of the cable significantly improved), thus extending the service life of the cable, fundamentally improve the quality of cable products and qualification rate.
5) Electricity saving (because of high work surface finish)
Adoption of nano coating compacting dies saves machine power consumption compared with traditional dies due to the improved working surface finish of the die and reduced friction between the dies and stranded wire, thus pulling cables of the same length.
Application cases:
- After the exploration and practice of Shanghai Huapu Cable Co., Ltd, Jiangsu Far East Cable Group, and Jiangsu Shang Shang Cable Group, the working life of the dies is more than 300 to 500 kilometres and as high as 1,000 kilometres. It is 10 to 30 times the original carbide compacting dies.
- Shanghai Huaxin Lihua Cable Co., Ltd. technical department in 2004, found that the production of 240mm2 cable, the use of aperture 18.4mm diamond coated compacting dies, after weighing and monitoring the comparison, then the use of tungsten carbide dies to save copper 1% ~ 1.5%, saving copper costs 20-30 million yuan (test production of the company is not known), so it seems that the cost of moulds can be ignored!
- Nexans and ABB in the United States reflect that copper can be saved by about 2 percent. The United States Nexans told us: that 90% of the cost of cable products is copper (aluminium) material, saving copper (aluminium) material 2%, which means that the cost reduction of 1.8% (90% × 2%). Before the product price of profit only accounted for about 3%, that is, the cost of about 97%, that is to say, in saving mould costs and improving product quality based on saving 1.7% (97% × 1.8%) of the cost-price ratio, that is, an increase of 1.7% of the profitability, which is equivalent to an increase of 57% over the original (1.7% ÷ 3%) of the profit!
- Shanghai Huapu Cable Co., Ltd. in 2004, a total of about 80 diamond coating compacting dies, according to statistics annual savings of about 8 million yuan of copper costs (each about the mould to save copper about 100,000 yuan).
Learn more about our Nano diamond coated dies products.
You might also be interested in this article: “Nano Dies vs PCD Dies vs Carbide Dies.”
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