Pagsusuri sa Kalidad ug Paghunahuna sa Mga Test para sa Electrical Cable

2yrs + staff 1000+m² US$300,000,000+ China

I. Pangunguna sa Problema
Ang mga kable elektriko ang pangunahing medium ng paghahatid ng sistema ng kuryente. Ang kalidad ng kanilang performance ay direktang nagpapasya sa estabilidad ng paghahatid ng kuryente, seguridad ng operasyon, haba ng buhay ng mga kagamitan, at kakayahan na iwasan ang mga aksidente tulad ng sunog. Ang mga hindi maayos na kable ay nagdudulot ng serye ng malubhang problema, kasama ang pagtaas ng resistensya, sobrang init, pagkasira ng insulasyon, taas na panganib ng sunog, at paglala ng signal interference. Kaya, mahalaga ang pagtatatag ng siyentipiko, mahigpit, at komprehensibong sistema ng kontrol sa kalidad at pagsusuri na nakakakita mula sa raw materials hanggang sa tapos na produkto.

II. Layunin ng Pagsusuri

Pagtitiyak ng Pinagmulan: Siguruhin na ang lahat ng raw materials na ginagamit sa produksyon ng kable ay sumasang-ayon sa pinakamataas na pambansang at industriyal na pamantayan (halimbawa, GB/T 3956, GB/T 12706, GB/T 19666, etc.).
Kontrol sa Proseso: Epektibong pantayin ang mga key process parameters at kalidad ng intermediate stages sa panahon ng produksyon.
Reliabilidad ng Produkto: Siguruhin na ang lahat ng key performance indicators ng tapos na kable - kasama ang electrical, physical & mechanical, at fire performance - ay sumasang-ayon o lumalampas sa design at kontrata requirements.
Paghahandle ng Panganib: Matukoy ang potensyal na defect sa pamamagitan ng sistemang pagsusuri upang iwasan ang pagpasok ng mga di-magkakatugmang produkto sa merkado at bawasan ang panganib sa paggamit.
Traceability: Itatag ang buong sistema ng quality testing record upang makamit ang traceability ng key material batches at resulta ng pagsusuri ng produkto.

III. Core Solutions: Kontrol sa Kalidad at Pagsusuri ng Electrical Cable

(A) Kontrol sa Kalidad at Pagsusuri ng Raw Material (Source Control)

1. Pagkakwalipikahan at Pagtatasa ng Supplier:

Piliin ang mga kwalipikadong supplier na may maayos na Quality Management System (halimbawa, ISO 9001 certification), matatag na kakayahang mag-supply, at mabuting reputasyon sa industriya.
Gumawa ng regular na unannounced sampling inspections o third-party verification ng mga materyales ng supplier.

2. Pagsusuri ng Key Raw Materials:

Conductor Material (Copper/Aluminum Rod/Wire):

Mga Item na Sususuriin: Analisis ng chemical composition (copper content, impurity elements), mechanical properties (tensile strength, elongation, repeated bending), resistivity measurement (at 20°C).
Standard Reference: GB/T 3953 (Round Copper Wire for Electrical Purposes), GB/T 3954 (Aluminum Rods for Electrical Purposes), GB/T 3956 (Conductors of Insulated Cables), etc.
Mga Paraan ng Pagsusuri: Chemical analyzers (halimbawa, spectrometer), tensile testing machine, Wheatstone bridge, o precision resistance meter.

Insulation and Sheath Materials (PVC, XLPE, PE, LSZH, etc.):

Mga Item na Sususuriin:

Physical Properties: Appearance, density, thickness uniformity, tensile strength & elongation at break, performance comparison before/after aging.
Electrical Properties: Volume/surface resistivity.
Thermal Properties: Heat deformation, hot set test (for XLPE), low-temperature impact/bend test.
Fire Performance (for LSZH/Flame Retardant Materials): Oxygen index, smoke density, acid gas content, halogen content (for halogen-free requirement).

Standard Reference: GB/T 8815 (Unplasticized Polyvinyl Chloride Compounds), GB/T 15065 (Crosslinked Polyethylene Insulation Compounds), GB/T 18380 (Tests on Electric Cables Under Fire Conditions - Single Flame Test), GB/T 17651 (Measurement of Smoke Density), GB/T 17650 (Halogen-free, Low-smoke Materials and Products), and other applicable standards.
Mga Paraan ng Pagsusuri: Universal material testing machine, aging oven, resistivity tester, hot set test device, oxygen index analyzer, smoke density chamber, chemical analyzers.

Shielding Material (Copper Tape/Wire): Thickness, resistance, coverage rate.
Filling/Bedding Materials: Water resistance (if applicable), mechanical strength, compatibility.

3. Mga Requirement sa Pagsusuri:

Ang lahat ng papasok na raw materials ay dapat kasama ang Certificate of Analysis (COA)/Certificate of Conformity (COC) ng supplier.
Gawin ang batch sampling inspection sa pagdating batay sa defined sampling plans (halimbawa, GB/T 2828.1). Ang sampling frequency maaaring itaas o gawin ang full batch inspection para sa critical materials (halimbawa, conductor, main insulation material).
Ang mga raw materials na nagsasabog sa pagsusuri ay estrictong ipagbabawal na gamitin sa produksyon.

(B) Kontrol sa Kalidad ng Proseso ng Produksyon (Process Monitoring)

1. Pantayin ang Key Process Parameters:

Conductor Stranding: Lay ratio, outer diameter, compaction (conductor).
Extrusion Process: Temperature settings and control per zone, extrusion pressure, line speed, cooling process (significantly impacts crystallinity).
Cross-linking Process (for XLPE): Irradiation dose/vulcanization temperature & time (critical for degree of cross-linking), cooling conditions.
Shielding Process: Coverage rate, overlap quality.
Cabling: Lay length, core stability.
Sheath Extrusion: Thickness uniformity, surface quality, printing legibility.

2. Sampling ng Proseso:

Itatag ang online o offline inspection points sa critical stages (halimbawa, after extrusion, cross-linking, cabling, sheathing).
Common Sampling Items: Insulation/sheath thickness and eccentricity, outer diameter, structural dimensions, appearance (surface defects), spark test / withstand voltage test (online/offline), partial physical property sampling (halimbawa, tensile).

(C) Kontrol sa Kalidad at Pagsusuri ng Tapos na Kable (Final Verification)

1. Type Testing (for new products or first batch of important contracts): Gawin ang lahat ng tests na inisyu sa relevant standards (halimbawa, GB/T 12706.1/2) upang komprehensibong patunayan ang conformity sa design.
2. Routine Tests (Per Batch / Per Drum / Per Reel):

Core Items:

Conductor DC Resistance Test: Sukatin ang resistance ng bawat conductor upang patunayan ang compliance sa nominal cross-section requirements (GB/T 3956). Ito ang pundamental para sa ampacity at heating calculations.
Partial Discharge Test (Essential for MV/HV cables): Matukoy ang minutong mga defect sa loob ng insulasyon na maaaring humantong sa long-term failure (GB/T 3048.8, GB/T 12706). Extremamente Mahalaga!
Voltage Test (Withstand Voltage Test):

Power Frequency AC Withstand Voltage: Pinakakaraniwan. Ilapat ang multiple rated voltage (halimbawa, 2.5U₀) para sa ispesipikong oras (halimbawa, 5 min). Ang insulasyon ay hindi dapat masira.
DC Withstand Voltage (Specific applications): Ginagamit para sa ilang uri ng kable o bilang supplement sa AC tests.

Insulation Resistance Measurement: Sukatin ang resistance sa pagitan ng conductor at shield/metallic sheath/earth, na nagpapakita ng basic insulating properties ng insulasyon material (GB/T 3048.5/6).

3. Sample Tests (Batch Sampling or Periodic Tests):

Electrical Performance:

Capacitance measurement (if applicable).
Dielectric loss tangent (tan δ) measurement (especially for HV cables).

Structural Dimensions and Physical Properties:

Insulation and sheath thickness measurement: Siguruhin ang compliance sa minimum design requirements.
Outer diameter measurement: Kontrolin ang tolerances.
Physical & Mechanical Performance Tests:

Tensile Strength and Elongation at Break (insulation/sheath) before/after aging: Key indicators, reflecting material's anti-aging capability and toughness (GB/T 2951.1).
Hot Set Test (Essential for XLPE insulation): Verify the degree of cross-linking compliance (GB/T 2951.21).
Low Temperature Impact/Bend Test: Assess material brittleness at low temperatures.
Flexing/Bending Test: Simulate installation and operating conditions to test cable flexibility (GB/T 12527).

Bending Test: Verify the cable's minimum allowable bending radius (usually performed on finished cable).
Fire Performance Tests (As per design requirements):

Single vertical flame test (GB/T 18380.1 series).
Bunched flame test (GB/T 18380.3 series).
Smoke density test (GB/T 17651).
Halogen-free, Low-smoke performance tests (Acid gas content, pH value, conductivity, light transmittance, halogen content - GB/T 17650).

Structural Examination: Conductor structure, shield coverage rate, core arrangement, filling density, metallic armor layer (dimensions, lay length, overlap gap), etc.

4. Testing Process:

Assign unique identification per finished cable batch/drum/reel.
Select representative samples according to defined sampling plans (per GB/T 2828.1 or contract requirements).
Conduct tests in accredited laboratories, adhering to current and valid national standards, industry standards, enterprise standards, or contract technical agreements.
All test items must have clearly defined pass/fail criteria.
Record test results in the finished product test report.

(D) Third-Party Verification and Inspection (Optional but Recommended)

For major projects, high-value cables used in critical locations, or upon specific user request:

Engage accredited independent third-party testing institutions (e.g., with CNAS/CMA accreditation) to perform sampling/re-testing of incoming materials or finished products.
Commission professional inspection agencies to witness and conduct on-site observation (audit/surveillance) during cable production (especially key processes) and final testing.

IV. Quality Testing Agency and Equipment Assurance

Accreditation: Laboratories performing testing tasks must possess relevant accreditation (e.g., CNAS, CMA).
Equipment Requirements: Equipped with comprehensive, fully functional testing equipment of requisite accuracy, regularly calibrated and verified (according to JJG procedures):

High-voltage test equipment (Power Frequency AC, DC, Impulse, Partial Discharge Systems).
Precision Bridges, Resistance Meters.
Universal Material Testing Machines (with high/low temperature chambers and aging ovens).
Hot Set Test Apparatus.
Fire Test Equipment.
Precision Measuring Tools (Calipers, Projectors).
Chemical Analysis Instruments (Spectrometer, Titrator, Ion Chromatograph, etc.).
Thickness Gauges (Laser, Ultrasonic).

Personnel Requirements: Testing personnel must be professionally trained, proficient in standards and operating procedures, and hold valid certification.

V. Handling of Non-Conforming Products

Identify and isolate any product found non-conforming during any stage (raw material, process, finished goods).
Conduct non-conformance review to analyze the root cause.
Based on the review conclusion, implement one of the following actions: Re-work/Repair (if feasible upon evaluation and core performance is unaffected), Downgrade/Use as Concession (only for non-critical scenarios with user approval), or Scrap.
Strictly prohibit non-conforming products from reaching the project site in any form.

VI. Records and Traceability

Establish complete electronic and physical backup records of all inspections, including at least:

Raw Material Supplier Information, Batch Number, Purchase Order Number, Raw Material Test Reports.
Production Batch Number, Operation Logs (Key Parameters), Process Inspection Records.
Finished Product Identification (Type, Specification, Length, Manufacturing Date, Batch/Drum/Reel No.), Complete Finished Product Test Report (covering all mandatory and optional test results), Copy of Type Test Report (if applicable).
Third-Party Test/Inspection Reports.

Maintain archives for the defined period (typically not less than the product's expected lifecycle) to ensure product quality traceability. In case of quality issues, enable rapid tracing back to raw material batches, production conditions, and test data.

07/31/2025

Gipareserbado

Mas daghan pa