The appearance of mining cables plays a crucial role in determining their overall quality. For inspectors, conducting a thorough visual examination is not an easy task. The ability to accurately assess the scale and severity of surface defects requires experience and proper training. If the same product is inspected by different individuals, varying conclusions may arise due to differences in interpretation. The visual quality of mining cables is essential because it forms the first impression of the product’s quality. Therefore, all high-quality products must pay close attention to their appearance.
Visual inspection of mining cables is a critical step in quality control. It involves checking the surface condition of finished products, semi-finished items, or raw materials. Inspectors must be well-versed in the standards and able to identify any irregularities that could affect performance. Although this process can be challenging, with careful study, experience, and the use of standard samples, inspectors can significantly improve accuracy and consistency.
1. **Round Copper Wire**: Inspect the surface for smoothness, checking for triangular mouth, burrs, cracks, folds, inclusions, severe spots, pits, and corrosion. Oxidation is also an important factor. A golden yellow color is normal, while light red indicates slight oxidation, and dark red or blue suggests severe oxidation. Any serious oxidation should result in rejection. Aluminum wire manufacturing requires strict control, especially when used in overhead transmission lines.
2. **Round Aluminum Rod**: Check for roundness and look for defects such as hemming, cracks, inclusions, kinks, mechanical damage, pits, skinning, flashing, and corrosion spots.
3. **Aluminum Wire Surface**: Ensure the wire is tightly twisted without looseness, kinks, jumps, bumps, or breaks. Welded joints should be smooth, with anti-corrosion treatment applied. The enlarged part of the joint should not exceed twice the diameter tolerance. The length of two welded joints should meet standard requirements, with at least 15 meters between them. Inner layers should have no less than 5 meters, and outer layers no less than 15 meters. When the copper core is made of a single wire, welding is not allowed.
4. **Appearance and Structural Dimensions of Mining Cables**: These are often checked together. The quality of the product is not only determined by its performance but also by its appearance and dimensions. Even minor issues like local thinning can lead to increased resistance and accelerated insulation aging. Rust spots can affect conductor joints and increase resistance, leading to faster insulation degradation. Bruises or scratches can reduce the mechanical strength of the conductor.
Visual inspection focuses on the surface condition, while dimensional inspection evaluates each part against specified standards. Structural inspection checks the internal components of the cable. For example, oxidation on copper wire can impact the cable's performance. Dimensional accuracy directly affects electrical properties—such as conductor diameter affecting resistance, insulation thickness influencing voltage withstand, and strand pitch affecting flexibility. Structural inspection helps identify production flaws, ensuring the final product meets required quality standards. Controlling both appearance and structural dimensions is essential to guaranteeing the performance and reliability of mining cables.
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