Litang Cable LAN/Ethernet Ethernet Cable Manufacturing Process.
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Litang Cable has 10 years of LAN/Ethernet Cable manufacturing experience, we passed the ISO9001 quality management system certificate, in the whole cable manufacturing process,we control each process to ensure products in good quality. The quality of the network cable produced by our professional LAN/Ethernet Cable manufacturing process is stable, safe and reliable. The following is the whole manufacturing process of our cable.

Step 1: Wire Drawing

1. Wire Drawing,Reducing the Diameter of Copper Wire (Wire Drawing Machine).
wire drawing
We know that the most important raw material for manufacturing LAN/Ethernet cable is copper wire, and the most important thing for copper wire is wire drawing, the size of which needs to be controlled by molds. Different molds can pull out copper wires of different sizes to achieve the desired size. We draw the large copper wire into the small copper wire to increase the length, reduce the diameter, but remain same volume. 
And the lubricant will be added to the die to reduce the temperature of the copper wire in the process of drawing, to prevent the copper wire from overheating and deformation, and can prolong the life of the die.
Finally, the copper wire will be drawn into copper coils of different diameters, such as 12AWG, 14AWG, 16AWG, etc.

2.Wire Drawing, Once Again Reducing the Diameter of Copper Wire (Wire Drawing machine).
Next, the second wire drawing before insulation is carried out, and the size is drawn to the desired diameter size, such as 22AWG, 24AWG, 26AWG and other required dimensions. And the equipment controller monitors the quality, diameter, concentricity and PE insulation diameter shape of the copper wire.

Step 2: Annealing the Copper Wire to Soften the Copper Wire and Increase the Ductility.

At this stage, the copper wire immersed in water will be heated to 1000 degrees F, and then quickly removed from the water for annealing, the annealing process is the process of softening the copper wire, increasing the softness and ductility of the copper wire, and can prevent the the copper wire from oxidation and corrosion.

Step 3: Extruding Copper Wire and Insulating (Extruder, Sheath Machine).

This step requires the copper wire to pass through the extruder, where single or double plastic particles are placed, and the HDPE particles are heated and melted in the extruder, then covers to the surface of the copper wire for insulation.

Step 4: Wire Insulation Diameter Testing (calipers and performance testers).

testing
In the fourth step, during the insulation process, we will test the insulation diameter of the copper wire and reduce the initial section of the wire to test the electrical characteristics, resistance and capacitance. After the test is qualified, the next process can be carried out. If the test is unqualified, the machine should be stopped for rectification.

Step 5: Twisting and Stranding Wire (twisting machine).

对绞2 twist pair cabling
In this process, two insulated wires of different colors are twisted in order to avoid crosstalk and interference in signal transmission, and each pair has a unique stranded length, and then electrical tests are carried out on the twisted pair, such as crossover, short circuit, open circuit etc,.

Step 6: Cabling (Cabling machine).

芯线2 cabling
The twisted cables are assembled on the cabling machine to form multiple pairs of stranded cable cores, which ensure that electrical interference can be controlled on rotating core equipment, and finally improve the flexibility of the wires.

Step 7: Jacketing(Jacketing machine)

成缆5 final cabling
According to different kinds of cables, there are several different steps, such as Cross Filling, Metal Sheath Filling, Braided Wire Filling,Drain Wire Filling,Rid Cord Filling, Printing and so on, which are in order to produce the kind of cable needed finally.

Cross Filling (Separator filling).
The twisted cables are heated to ensure that the cross can pass through the possible gaps and,finally, wrap the cable around the cross.

Metal sheath filling.
Depending on the design of the cable, some cables require a protective metal sheath made of aluminum foil or steel. As a way to prevent the interference of static electricity to the signal in high voltage, aluminum foil has the functions of shielding, anti-radiation, anti-static and so on. Metal is designed to protect buried cables under the ground from damage by rats or other animals such voles.

Braided Wire Filling.
High Speed Braiding Machine
Now, due to the more interference of the signal and the design of different network cables, a layer of Braided Shield will be added in the network cable, which plays the role in preventing the interference caused by static electricity to the signal, with shielding, anti-radiation, anti-static effect.

Drain Wire Filling.
Due to the damage caused by high voltage to the cable, some network cables will be designed with a drain wire, to discharge the induced or interference current as soon as possible, or to make the electric potential of the entire shield as equal as possible. Generally speaking, braided shielding is not needed, but separate braided shielding, because its cross-sectional area is very small, if there is no drain wire, the electric potential on the whole cable length may not be equal, which will produce interference current.
According to different designs, without braided shield, the aluminum foil is wrapped, the drain wire is placed into the aluminum foil, and the wire is dragged into when the wire is cabled, and the drain wire is in contact with the aluminum surface of the aluminum foil (aluminum facing inward).
In the case of braiding, the drain wire is placed onto the aluminum foil with the braided shield, and the aluminum surface faces outward.

Rid Cord Filling.
High-quality network cables such as CAT6A,CAT7 CAT7A CAT8, generally there are a fiber called Rid Cord, which is not helpful to signal transmission at all. It can be used to peel the wire quickly when workers pull the wire skin without damaging the twisted pair.

Outer Cable Jacketing.
护套3 Serial Machine - PE Insulation
Then there is the outer cable sheath jacketing. According to different needs, the outer sheath generally has PE,PVC,LSZH and so on.
Indoor LAN/Ethernet cable is divided into two layers of skin, the inner skin refers to the plastic skin wrapped in copper wire with PE material, PE material is non-toxic, easy to color, good chemical stability, cold resistance, radiation resistance, good electrical insulation.Polyethylene (PE) is insoluble in any known solvent at room temperature, and resists to dilute sulfuric acid, dilute nitric acid and other acids of any concentration, as well as various concentrations of alkali and salt solutions. PE is UV resistant and PE can protect cables underground or when utility poles are in use in exposed sunlight.
The outer skin refers to the mesh epidermis we see, which is made of PVC. Generally, the new material or secondary material will be used according to the quality of the cables. The pvc chemical stability of the new material is good, and it is resistant to acid, alkali and some chemicals. It is moisture-resistant, aging-resistant and non-flammable (flame retardant). When it is used, the temperature should not exceed 60 ℃, and it will harden at low temperature. Sometimes it will be introduced that we use a new material of 75 degrees. In fact, 75 degrees does not refer to the temperature, but refers to the softness and hardness of PVC.

Cooling and Printing.
喷码机4printing machine
The final process is that after the jacketing, the cable will pass through the water tank where the temperature is controlled by the main controller and cool the sheath. When the cable is dry and the outer layer of the sheath is slightly hot, you can use the ink-jet printer to print fonts or marks on it.
structure cat6

Step 8: Pre-shipment Testing.

pre-shipment-testing-1
pre-shipment-testing-2
After assembling, the cable is twined around a metal or wooden reel and transported to the testing facility for testing.
We will use a Fluke test on the cable, the test content is as follows.
NEXT (near segment crosstalk)-the amplitude difference between the transmitted signal and the crosstalk received on other pairs at the same end of the wiring (in dB).
PS NEXT (power and attenuation-Next)-the difference between the test signal and the crosstalk of other wire pairs accepted in the same segment (in dB).
ACR-F (attenuation crosstalk ratio- FEXT)-calculates the insertion loss of the FEXT minus the interfered pair (in dB).
PS ACR-F (power and attenuation crosstalk ratio- FEXT)-the calculation of PS FEXT minus the insertion loss of the interfered pair (in dB).
ACR-N (attenuated crosstalk ratio-Next)-calculation of NEXT minus insertion loss of interfered pairs (in dB).
PS ACR-N (power and attenuation crosstalk ratio- Next)-calculation of PS NEXT minus insertion loss of interfered pairs (in dB).
RL(Return Loss)-the difference between the transmitted signal power and the reflected signal power (in dB).

Step 9: Packing.

packing
Under normal circumstances, the produced cable of metal reel is then divided into a roll of 1000ft according to the demand, and then the cable will be installed into the Easy-Pull Box. According to the requirements of different clients, the general packaging methods are as follows:
● Coil.
● Plastic Reel.
● Wooden Reel.
● Carton.
● Reel-In-A-Box.
● Easy-Pull Box.

Step 10: Delivery.

The tested cables will be palletized and loaded into cabinets, and some will add steel caps or plastic caps to seal the ends of the cables to protect them from moisture during shipping.
If you would like to have a question then get in touch today, we are ready to assist 24/7.
We welcome your cooperation and we will develop with you.

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