无卤低烟0.6-1.doc

QB 焦作同心电缆有限公司技术文件Q/TXDL-GY-006-2011 0. 6/1 kV低烟无卤绝缘聚氯乙烯护套 电力电缆工艺2011年1月5日编制 2011年2月5日执行焦作同心电缆有限公司技术质量部编制0.6/1kV 低烟无卤绝缘电力电缆生产工艺编制说明1. 本文件执行标准为 GB/T12706.1-2008.2.本文件自2011年1月10日下发后，1月10日-2月5日为实行期，2月5日正式执行。3.自本文件下发之日起，本产品所下发的临时工艺文件即行作废，不再执行。4.本文件有关内容的解释权在技术质量部。批准审核标准化校核编制会签0.6/1kV 低烟无卤绝缘聚氯乙烯护套电力电缆工艺流程图退火线芯工艺拉丝成缆铠装绝缘挤制护套挤制成品验收、包装工艺成品检验入库火花检验检检检检检检检检：代表关键工序质量控制点。绝缘挤出为关键工序质量控制点0.6/1kV 低烟无卤绝缘电力电缆拉丝工艺1.拉丝用铜杆采用符合GB/T3956-2008的第1种或第2种镀金属层或不镀金属层退火铜导体、或第5种裸铜导体或镀金属层退火铜导体。2.成品单线应光洁不得有斑痕，裂痕等缺陷，不允许表面有严重刮伤现象。3.成品单线不得有明显油污，不得有与良好工业品不相称的任何缺陷。4.收线盘最外层线应距侧板边缘20mm以上，以防线材表面损伤。5.中间拉丝模应采用硬质合金模，为提高模具使用寿命和产品质量，成品模可采用聚晶模。6.成品模超差在没有修制超差时，不允许中间过模使用。0.6/1kV 低烟无卤绝缘电力电缆圆铜单线拉制工艺铜圆单线型号：TY生产设备铜拉丝机线芯结构线芯规格mm2单线直径mm2圆铜线拉制配模表铜杆直径mm12345678910111213公差非紧压圆形绞合导体101.358.007.005.905.004.253.653.152.752.412.141.901.701.521.351%d161.708.007.005.905.004.003.653.152.752.412.141.901.70紧压圆形绞合导体25,702.268.006.805.654.754.003.453.002.602.2635,95,1852.678.006.805.654.754.003.453.002.6750,120 ,2403.048.006.805.654.754.003.453.04150,300,5003.368.006.805.804.954.303.753.364002.968.007.005.905.004.253.653.152.966303.728.007.005.905.004.253.72半圆形，扇形紧压绞合导体252.248.006.805.654.754.003.453.002.602.2435,50,70,95,120,150,185,240,300,4002.578.006.806.005.254.604.053.603.202.852.570.6/1kV 低烟无卤绝缘电力电缆铜线软化工艺产品退火温度（）保温时间（min）冷却方式退火后质量要求工艺要求圆铜线360-43090-150自然冷却2-4h圆铜线退火后：直径为：1.35-2.99mm 其伸长率25%直径为：3.04-3.35mm 其伸长率30% 电阻率200.017241mm2/m圆铜单线表面不允许有明显的氧化现象及其他机械外伤。0.6/1kV 低烟无卤绝缘电力电缆线芯绞合工艺1. 圆铜单线采用符合GB39532009标准要求的TR型软圆铜线，铜单线不得有明显的油污，外伤及表面氧化变色等缺陷。2. 铜导电线芯性能符合GB/T39562008标准规定。3. 铜导电线芯性不允许整根焊接，同层两根单线焊接点之间的距离不得小于30mm，焊接点应牢固，修复圆整。4. 绞合导电线芯不允许跳线、断线、严重的油污、外伤等现象，断线处用红胶带做好标记，外径正公差处修复到公差以内，在质量跟踪卡上注明修复点位置。5. 成品紧压绞合线芯外观应紧密，圆整，光洁，扇形线芯的接角应为小圆弧状，外径符合工艺要求。6. 紧压导电线芯截面采用称重法测量，其截面小于规定最小值，则用20直流电阻值做仲裁判定。7. 非紧压线芯以控制单线直径为主。8. 线芯绞合节距在本工艺要求范围内允许5mm误差。0.6/1kV 低烟无卤绝缘电力电缆导电线芯的截面控制和直流电阻紧压绞合导电线芯标称截面(mm2)2535507095120150185240300400500630铜芯截面控制mm2最小24.734.346.467.093.0117.3144.8181.2238.1298.7381.3489.5628.2最大26.035.848.269.095.0119.5147.2183.8240.9301.7400.3499.4630.120时直流电阻不大于/Km0.71980.51880.38220.26530.19110.15150.12280.09810.07470.05950.04660.03630.0282铝芯截面控制mm2最小23.832.944.564.589.3112.9138.6174.0228.3285.5366.6470.3607.8最大25.134.446.466.591.3115.1141.0176.7231.2288.5384.9493.8626.120时直流电阻不大于/Km1.18810.85940.63470.43860.31680.25050.20390.16240.12380.09900.07710.06010.0465实心、非紧压绞合圆形导电线芯标称截面(mm2)1.52.546101620时直流电阻不大于/Km铜芯12.17.414.613.081.831.15铝芯18.112.17.414.613.081.910.6/1KV低烟无卤绝缘电力电缆铜芯圆形线芯绞合及圆形紧压线芯绞合工艺一芯、五芯 WDZC-YJY生产设备500、630框绞机标称截面mm2结构单线 直径 mm12盘绞笼18盘绞笼24盘绞笼紧压后直径压模直径mm节距mm方向压模直径mm节距mm方向压模直径mm节距mm方向标称直径mm最大直径mm101+6/1.353.946-54左4.04.10161+6/1.705.060-70左5.05.15251+6/2.266.072-84左6.06.20351+6/2.677.084-98左7.07.20501+6/3.048.298-114左8.28.40701+6+11/2.266.995-108右9.8117-137左9.810.1951+6+11/2.678.1112-128右11.2134-156左11.311.81201+6+11/3.049.2127-146右12.7152-177左12.813.21501+6+11/3.3610.2141-161右14.2170-198左14.314.61851+6+12+17/2.6713.2182-208左13.4187-214右15.8189-221左15.916.72401+6+12+17/3.0415.1210-240左15.3214-244右18.0216-252左18.119.13001+6+12+17/3.3616.6231-264左16.8235-269右20.2242-282左20.321.34001+6+12+18+23/2.9614.7203-232左20.5287-328右23.2278-324左23.323.65001+6+12+18+23/3.3616.7231-264左23.2325-371右26.4316-369左26.526.86301+6+12+18+23/3.7218.5254-291左25.5357-400右30.0360-420左30.130.40.6/1kV 低烟无卤绝缘电力电缆扇形线芯绞合工艺三芯 WDZC-YJY WDZC-YJLY生产设备500、630框绞机标称截面mm绞合结构单丝直径6盘12盘18盘24盘铜mm铝mm压模直径mm节距mm方向压模直径mm节距mm方向压模直径mm节距mm方向压模直径mm节距mm方向扇形高mm压辊351+62.572.557.7100-110左5.92.5502+82.572.555.1115-125右10.2120-130左7.13.0704+102.572.556.1130-140右11.3135-145左8.53.7951+6+122.572.557.7115-170右12.8155-170左9.94.41202+8+142.572.555.1170-190左10.2170-190右18.0190-205左11.35.01504+10+162.572.556.1190-210左11.3190-210右20.0190-210左12.95.61851+6+12+182.572.557.7220-230左12.8220-230右22.5220-235左14.56.42403+9+15+212.572.555.5165-176右10.6250-260左15.6240-260右25.1260-275左17.27.13001+6+12+18+242.572.557.7230-246右12.8315-325左16.3310-330右28.1315-330左17.97.64001+6+12+18+232.982.968.7230-250右14.7315-325左17.6312-330右29.6315-335左18.48.30.6/1kV 低烟无卤绝缘电力电缆扇形线芯绞合工艺（3+1）主芯 WDZC-YJY生产设备500、630框绞机标称截面mm绞合结构单丝直径6盘12盘18盘24盘铜mm铝mm压模直径mm节距mm方向压模直径mm节距mm方向压模直径mm节距mm方向压辊压模直径mm节距mm方向扇形高mm压辊351+62.572.557.795-110左6.62.4502+82.572.555.1115-125右10.2110-128左7.13.0704+102.572.556.1130-140右11.3132-142左9.33.7951+6+122.572.557.7160-170右12.8150-163左10.64.41202+8+142.572.555.1170-180左10.2170-180右17.1185-200左12.15.01504+10+162.572.556.1180-200左11.3181-198右19.3185-200左13.15.61851+6+12+182.572.557.7220-300左12.8220-228右21.4220-230左14.76.42403+9+15+212.572.555.5170-180右10.6245-255左15.5235-245右7.224.2255-260左17.67.43001+6+12+18+242.572.557.7240-250右12.8311-321左17.7315-325右7.424.8315-325左19.47.64001+6+12+18+232.982.968.7242-252右14.7315-325左18.1312-330右7.729.7318-328左23.48.50.6/1kV 低烟无卤绝缘电力电缆扇形线芯绞合工艺（3+1）地芯 WDZC-YJY生产设备500、630框绞机标称截面mm绞合结构单丝直径6盘12盘18盘铜mm铝mm压模直径mm节距mm方向压模直径mm节距mm方向压模直径mm节距mm方向扇形高mm压辊251+62.232.246.780-95左6.42.2351+62.572.557.7100-110左7.63.2502+82.572.555.1115-125右10.2120-135左8.23.4704+102.572.556.1130-140右11.3135-150左9.74.2951+6+122.572.557.7155-170右12.8155-165左11.84.71202+8+142.572.555.1170-190左10.2170-1190右19.5190-200左13.45.41504+10+162.572.556.1190-205左11.3190-210右22.5195-205左15.56.61851+6+12+182.572.557.7220-228左12.8220-230右23.5200-210左15.97.30.6/1kV 低烟无卤绝缘电力电缆绝缘挤出工艺1. 绝缘挤出工艺分为单芯与多芯电缆的绝缘线芯挤出。2. 绝缘材料的技术性能符合GB/T12706-2008标准中低烟无卤绝缘料的要求。3. 绝缘层平均厚度应不小于规定的标准厚度，最薄点的厚度应不小于标称厚度的90%，即工艺给出的最薄点厚度。4. 生产过程中，挤出厚度均匀，挤包密实，外表光滑，无杂质，绝缘层的断面上应无目力可见的气泡、砂眼等缺陷。5. 绝缘线芯的识别标志，应符合GB6995.5-2008的规定，其规定为：2芯电缆红、浅蓝；3芯电缆红、黄、绿；4芯电缆红、黄、绿、浅蓝；6. 绝缘技术性能应符合GB/T12706-2008标准中的规定。7. 严格按工艺要求及生产计划用工艺盘具，并应保证制造长度。8. 凡绝缘线芯质量有缺陷位置应在周转卡上标明，并用易区分的彩色胶带做好标记。0.6/1kV 低烟无卤绝缘电力电缆绝缘挤出工艺单芯 五芯 WDZC-YJY生产设备50、65、80、90挤出机标称截面mm2扇形高（直径）mm绕包云母带10.05包带外径mm绝缘层外径控制围mm模具火花检验电压kV标称厚度mm最薄点mm模芯mm模套mm104.0104.20.70.535.26-5.606.512.06165.0105.20.70.536.26-6.607.513.06256.0106.20.90.717.62-8.008.515.06357.0107.20.90.718.62-9.009.516.06508.2108.41.00.8010.0-10.410.517.010709.810101.10.8911.78-12.212.520.0109511.31011.51.10.8913.28-13.81421.01012012.810131.20.9814.96-15.415.523.01015014.31014.51.41.1616.82-17.31725.01018515.91016.11.61.3418.78-19.31928.01524018.11518.31.71.4321.16-21.72130.01530020.31520.51.81.5223.54-24.12333.01540023.31523.52.01.7026.9-27.528.135.11550026.51526.72.21.8830.46-31.131.739.12063030.11530.32.42.0634.42-35.135.743.520注：绝缘用的是无卤低烟材料0.6/1kV 低烟无卤绝缘电力电缆绝缘挤出工艺二芯 WDZC-YJY生产设备50、65、80、90、挤出机标称截面mm2扇形高（直径）mm绕包云母带10.05包带外径mm绝缘层外径控制围mm模具火花检验电压kV标称厚度mm最薄点mm模芯mm模套mm104.0104.20.70.535.26-5.66.5126165.0105.20.70.536.26-6.67.5136256.0106.20.90.717.62-8.08.5156355.0105.20.90.716.62-7.012.5186506.0106.21.00.807.80-8.213.5206707.2107.41.10.899.18-9.615.52310958.5108.71.10.8910.48-11.119.527101209.6109.81.20.9811.76-12.221.5291015010.71010.91.41.1613.22-13.724.5331018511.51011.71.61.3414.38-14.925.53415注：绝缘用的是无卤低烟材料0.6/1kV 低烟无卤绝缘电力电缆绝缘挤出工艺三芯 WDZC-YJY 生产设备50、65、80、90挤出机标称截面mm2扇形高（直径）mm绕包云母带10.05包带外径mm绝缘层外径控制围mm模具火花检验电压kV标称厚度mm最薄点mm模芯mm模套mm104.0104.20.70.535.26-5.66.5126165.0105.20.70.536.26-6.67.5136256.0106.20.90.717.62-8.08.5156355.9106.10.90.717.52-7.9013.5206507.1107.31.00.808.90-9.3015.5226708.5108.71.10.8910.48-10.9017.5.2510959.91010.11.10.8911.88-12.3021.5291012011.31011.51.20.9813.46-13.9023.5311015012.91013.11.41.1615.42-15.9026.5351018514.51014.71.61.3417.38-17.9028.5381524017.21517.41.71.4320.26-20.8032.5421530017.91518.11.81.5221.14-21.7034.5441540018.41518.62.01.7022.0-22.6036.54615注：绝缘用的是无卤低烟材料0.6/1kV 低烟无卤绝缘电力电缆绝缘挤出工艺（3+1）主芯 WDZC-YJY生产设备50、65、80、90挤出机标称截面mm2扇形高（直径）mm绕包云母带10.05包带外径mm绝缘层外径控制围mm模具火花检验电压kV标称厚度mm最薄点mm模芯mm模套mm104.0104.20.70.535.26-5.66.5126165.0105.20.70.536.26-6.67.5136256.0106.20.90.717.62-8.08.5156356.6106.80.90.718.22-8.613.5206507.8108.01.00.809.60-10.015.5226709.4109.61.10.8911.38-11.817.525109510.91011.11.10.8912.88-13.321.5301012012.11012.31.20.9814.26-14.723.5311015013.41013.61.41.1615.92-16.426.5351018515.11015.31.61.3417.98-18.528.5381524017.61517.81.71.4320.66-21.232.5421530019.41519.61.81.5222.64-23.234.5441540022.61522.82.01.726.2-26.838.54715注：绝缘用的是无卤低烟材料0.6/1kV 低烟无卤绝缘电力电缆绝缘挤出工艺（3+1）地芯 WDZC-YJY生产设备50、65、80、90、挤出机标称截面mm2扇形高（直径）mm绕包云母带10.05包带外径mm绝缘层外径控制围mm模具火花检验电压kV标称厚度mm最薄点mm模芯mm模套mm104.0104.20.70.535.26-5.66.5126165.0105.20.70.536.26-6.67.5136256.0106.20.90.717.62-8.012.5196357.6107.80.90.719.22-9.615.5226508.7108.91.00.8010.50-10.917.52567010.31010.51.10.8912.28-12.721.529109512.51012.71.10.8914.48-14.923.5311012014.21014.41.20.9816.36-16.826.5351015015.51015.71.41.1618.02-18.528.5381018515.91016.11.61.3418.78-19.330.54015注：绝缘用的是无卤低烟材料0.6/1kV 低烟无卤绝缘电力电缆成缆工艺1. 成缆应圆整，成缆的f值应不大于3%-2mm.2. 成缆扎紧绕包应紧密，不得松包，以免在衬层或护套挤制过程中因斡带造成脱胶。3. 双层包带采用相互搭盖绕包，以保证质量。4. 成缆线芯用并线模具可根据缆芯直径进行调整。5. 成缆过程中，一根电缆需在下道工序分头时，应用红色胶带作明显标记，并在工序自检卡上注明原因。6. 色序：红、黄、绿、浅蓝、黑色五色面对绞笼按顺时针排列。0.6/1kV 低烟无卤绝缘电力电缆成缆工艺二芯 WDZC-YJY生产设备1米、1.6米成缆机规格mm2绝缘后直径及扇形高mm成缆工艺成缆绕包工艺内衬层绕包工艺压模直径mm节距mm填充直径mm方向成缆外径mm无纺布规格层厚宽mm节距mm方向包带外径mmPVC带规格层厚宽mm节距mm方向包带外径mm2105.611.2407-49723.7右11.210.23028-34左12.030.21524-29右13.22166.613.2472-57624.4右13.210.23024-30左14.030.22029-35右15.2225816558-68225.3右1610.24033-40左16.830.22033-40右18.0235714632-77323.0右1410.23028-34左14.830.22028-34右16.02508.216.4734-89723.5右16.410.24033-40左17.230.22033-40右18.42709.619.2869-106223.5右19.210.24033-40左20.030.22045-56右21.229511.122.2961-119524.0右22.210.25036-44左23.030.23043-53右24.2212012.224.41071-130924.0右24.410.25040-49左25.240.23056-69右26.8215013.727.41251-152924.5右27.420.24056-68左28.240.24056-68右29.8218514.929.81350-165024.5右29.820.24060-73左30.640.24051-62右32.4注：填充直径为3.0mm及以下的为PVC填充绳，3.0mm以上的为PP填充绳。0.6/1kV 低烟无卤绝缘电力电缆成缆工艺三芯 WDZC-YJY生产设备1米、1.6米成缆机规格mm2绝缘后直径及扇形高mm成缆工艺成缆绕包工艺内衬层绕包工艺压模直径mm节距mm填充直径mm方向成缆外径mm无纺布规格层厚宽mm节距mm方向包带外径mmPVC带规格层厚宽mm节距mm方向包带外径mm3105.612.1429-52432.6右12.110.23027-32左12.930.21522-27右14.13166.614.2499-60933.0右14.210.23022-27左15.030.22031-38右16.23258.017.2633-77333.8右17.210.24039-48左18.030.22028-34右19.23357.917.0792-96833.0右17.010.24035-43左17.830.22030-37右19.03509.320.0918-112233.5右20.010.24035-42左20.830.23041-50右22.037010.923.51071-130933.5右23.520.24056-68左24.340.24056-68右25.939512.326.51251-152934.0右26.520.24056-68左27.340.24056-68右28.9312013.929.91350-165034.0右29.920.24051-62左30.740.24051-62右32.3315015.934.21575-192534.5右34.220.25070-86左35.040.24059-73右36.6318517.938.61835-224334.5右38.620.25069-84左39.450.25069-84右41.4324020.844.82061-252935.0右44.820.26062-76左45.650.25062-76右47.6330021.746.72155-263335.0右46.720.26065-79左47.550.35065-79右50.5340022.648.72155-263336.0右48.720.26065-79左49.550.35065-79右52.5注：填充直径为3.0mm及以下的为PVC填充绳，3.0mm以上的为PP填充绳。0.6/1kV 低烟无卤绝缘电力电缆成缆工艺(3+1)芯 WDZC-YJY生产设备1米、1.6米成缆机规格mm2绝缘后直径及扇形高mm成缆工艺成缆绕包工艺内衬层绕包工艺压模直径mm节距mm填充直径mm方向成缆外径mm无纺布规格层厚宽mm节距mm方向包带外径mmPVC带规格层厚宽mm节距mm方向包带外径mm316+1106.70/5.6515.5540-66042.2右15.510.23020-25左16.330.22028-34右17.5325+1168.10/6.7018.7680-83142.7右18.710.24030-37左19.530.22025-31右20.7335+1168.6/6.7019.9869-106243.0右19.910.24033-40左20.730.23045-56右21.9350+12510.0/8.423.1977-119543.5右23.110.25061-74左23.930.23043-53右25.1370+13511.8/9.627.31161-141943.5右27.320.24060-74左28.130.24060-74右29.3395+15013.3/10.930.71350-165044.0右30.720.24060-73左31.540.24051-62右33.13120+17014.7/12.734.01456-178044.0右34.020.24055-67左34.840.24055-67右36.43150+17016.4/12.737.91701-207944.5右37.920.25064-78左38.740.25064-78右40.33185+19518.5/14.942.71835-224344.5右42.720.25069-84左43.550.25069-84右45.53240+112021.2/16.849.02155-263345.0右49.020.25065-79左49.850.25065-79右51.83300+115023.2/18.553.62410-294645.0右53.620.25061-75左54.450.25061-75右56.43400+118526.8/19.361.92420-295646.0右61.920.25063-78左62.750.25063-78右64.7注：填充直径为3.0mm及以下的为PVC填充绳，3.0mm以上的为PP填充绳0.6/1kV 低烟无卤绝缘电力电缆成缆工艺五芯 WDZC-YJY生产设备1米、1.6米成缆机规格mm2绝缘后直径及扇形高mm成缆工艺成缆绕包工艺内衬层绕包工艺压模直径mm节距mm填充直径mm方向成缆外径mm无纺布规格层厚宽mm节距mm方向包带外径mmPVC带规格层厚宽mm节距mm方向包带外径mm5105.6515.3540-66013.9右15.310.23020-25左16.130.22028-34右17.35166.7018.1633-77352.5右18.110.24033-40左18.930.22028-34右20.15258.1021.9792-96853.0右21.910.24030-37左22.730.23041-51右23.95359.1024.61071-130953.4右24.620.24056-69左25.440.24056-69右27.055010.528.41251-152953.9右28.420.24056-68左29.240.24056-68右30.857012.333.21456-178054.6右33.220.24055-67左34.040.24055-67右35.659514.037.81701-207955.2右37.820.25064-78左38.64