As a key product in the power system that integrates both ground wire and communication functions, the Optical Fiber Composite Overhead Ground Wire (OPGW) demands stringent process control and precise quality management throughout its production. Taking the manufacturing practice of pioneergoods Optical Cable Manufacturer as an example, this article systematically elaborates on the complete production process of OPGW cables.
Raw Material Inspection and Preparation
The production process begins with a rigorous raw material inspection phase. All incoming metal wires, including aluminum-clad steel wires (ACSR) and aluminum alloy wires, must undergo multiple performance tests such as tensile strength, electrical conductivity, and elongation rate. For optical fibers, comprehensive inspections are conducted on their geometric dimensions, transmission performance, and mechanical properties. The rigorous control at this stage lays a solid foundation for the quality of subsequent production processes.
Optical Fiber Unit Manufacturing
In a clean workshop with constant temperature and humidity, the screened optical fibers enter the coloring process, where colored coatings are applied for fiber identification. Subsequently, the colored optical fibers, together with water-blocking materials, are encapsulated in sealed sleeves to form preliminary optical fiber units. This process imposes extremely high requirements on environmental cleanliness and process precision—any tiny impurity or damage may compromise the transmission performance of the optical fibers.
Metal Single Wire Processing
The processing of metal single wires is carried out simultaneously. Materials such as aluminum-clad steel wires and aluminum alloy wires undergo wire drawing, annealing, and other processes to achieve the diameter and mechanical properties specified in the design. Each batch of metal wires is subject to surface quality inspection to ensure the absence of scratches and oxidation, thus guaranteeing the smooth progress of the subsequent stranding process.
Stranding and Cabling
This is the core link in OPGW cable production. On specialized stranding equipment, metal single wires are stranded layer by layer in accordance with the predetermined structure, and the optical fiber units are accurately positioned in the designated locations. During the stranding process, parameters such as lay pitch and tension must be strictly controlled to ensure the cable structure is compact and the stress distribution is uniform. Meanwhile, water-blocking materials are filled synchronously to form an effective longitudinal water-blocking barrier.
Finished Product Testing and Validation
After the sheath extrusion, the finished OPGW cables are subjected to comprehensive performance tests:
- Mechanical performance tests: Including tensile strength, stress-strain characteristics, etc.
- Electrical performance tests: Covering DC resistance, short-circuit current capacity, etc.
- Optical performance tests: Including transmission indicators such as attenuation coefficient and bandwidth.
These tests ensure that every reel of outgoing cable meets the design requirements and relevant industry standards.
Packaging and Storage
The finished cables that have passed all tests are packaged using specialized cable reels. The reel structure is specially designed to prevent mechanical damage to the cables during transportation and storage. The packaging process also includes complete labeling work—each reel of cable is attached with detailed technical parameters and product information.
Continuous Process Optimization
The production of OPGW cables is a systematic project, where the precise control of each link directly affects the quality of the final product. Through standardized production processes, strict quality control, and continuous technological innovation, we ensure that OPGW cables can meet the dual requirements of the power system for communication and safety, providing reliable product support for the construction of smart grids.