The main steps in manufacturing a multi-core cable include the following:
(1) Cable length cutting. After analyzing the cable manufacturing requirements, the manufacturing drawings must be carefully checked, and the required cable model determined. Then, the cable length is cut according to the requirements.
(2) Cable pretreatment. After the cable length is cut, a test must be conducted to ensure that the connector end cover can pass through the cable. Once determined, the stripping length of the cable's outer layer is determined based on the length of the end cover. It is important to ensure that the arc apex is on the cable's insulation layer as much as possible to effectively avoid stress on the core wires. If the end cover cannot pass through the cable, the outer insulation layer of the cable must be symmetrically cut from both sides and turned outwards, then secured with cable ties to ensure that the end cover can pass through the cable.
(3) Shielding layer treatment. Due to practical needs, multi-core cables generally use shielded conductors as core wires. During the treatment process, usually one core wire is left to connect to the connector's outer shell.
(4) Marking determination. The markings are mainly divided into two types: cable markings and core wire markings. When determining cable markings, first select a suitable sleeve based on the cable's outer diameter, and then mark the sleeve. When determining core wire markings, determine the sleeve based on the core wire's thickness and the size of the solder cup. After marking the cable, insert a transparent heat-shrink tubing to preserve the markings and prevent them from becoming blurred or disappearing after a period of use, which would hinder subsequent work.
(5) Pre-treatment of the core wires. After the cable core wires have been stripped, determine the stripping length of the core wire insulation based on the length of the solder cup in the connector. Wire strippers are typically used during stripping, but care must be taken to avoid damaging the conductors. After stripping, the core wires should be inspected promptly to ensure their gloss. Once these procedures are completed, the cable can be tinned, but the timing must be accurate to ensure cable quality.
