We produce power cords every day, with daily output exceeding 100,000 meters of cable and 50,000 plugs. Given such large-scale production volumes, the manufacturing process must be highly stable and well‑established. Through continuous research and development, and with recognition from leading certification bodies—including Europe’s VDE, China’s CCC, the U.S.’s UL, the U.K.’s BS, and Australia’s SAA—the power cord and plug assembly has reached full maturity. Below is a brief overview:

1. Drawing of copper and aluminum single wires for power cables

Copper and aluminum rods, commonly used for power cables, are drawn at room temperature through one or more drawing dies, reducing their cross-sectional area, increasing their length, and enhancing their strength. Wire drawing is the first process in every wire and cable manufacturing company, and the primary process parameter is die‑matching expertise.

2. Single-wire annealing of the power cord

Copper and aluminum monofilaments are heated to a specific temperature, and their ductility is enhanced while their strength is reduced through recrystallization, thereby meeting the requirements for conductive wire cores in electrical cables. The key to the annealing process is to prevent oxidation of the copper wires.

3. Stranding of Power Cable Conductors

To enhance the flexibility of power cables for easier installation, the conductor core is constructed by stranding multiple individual wires. Based on the stranding configuration, conductors are classified as regular stranding and non‑regular stranding. Non‑regular stranding further includes bundle stranding, concentric double stranding, and special stranding, among others. To reduce the cross‑sectional footprint and minimize the cable’s overall dimensions, compacting techniques are employed during the stranding process, transforming a conventional circular shape into semi‑circular, sector‑shaped, tile‑shaped, or tightly compacted circular profiles. Such conductors are primarily used in power cables.

4. Insulation extrusion of power cords

Plastic power cables primarily use extruded solid insulation. The main technical requirements for plastic insulation extrusion are:

1) Eccentricity: The deviation of the extruded insulation thickness is a key indicator of extrusion quality, and for most products, both the dimensional specifications and their permissible deviations are clearly defined in the relevant standards.

2) Lubricity: The extruded insulation layer shall have a smooth surface, with no defects such as roughness, scorching, or impurities.

3) Density: The cross-section of the extruded insulation layer shall be dense and robust, with no pinholes visible to the naked eye and no bubbles present.

5. Power cords are routed in a neat manner.

For multi-core power cables, in order to ensure proper shaping and minimize the cable’s cross-sectional profile, it is generally necessary to twist the conductors into a circular configuration. The twisting mechanism is similar to that of conductor stranding; however, due to the relatively large lay length, a non‑retwisting method is typically employed. The technical requirements for cabling are as follows: first, prevent the irregularly shaped insulated cores from turning over, which could cause the cable to become twisted or kinked; second, avoid scratching the insulation layer.

Most cables, during the cabling process, are also subjected to two additional operations: one is filling, which ensures the cable’s roundness and dimensional stability after cabling; the other is stranding, which prevents the cable core from becoming loose.

6. Inner sheath of the power cable
To prevent the insulated conductor cores from being damaged by the armor, appropriate protection of the insulation layer is required. The inner protective layers are classified into extruded inner protective layers (isolation jackets) and wrapped inner protective layers (padding layers). The wrapped padding layer is applied in place of binding tapes and is carried out concurrently with the cable‑stranding process.

7. Armored power cable
Underground power cables, when subjected to significant axial compressive forces during operation, may be equipped with an internal steel‑tape armor. For installations where the cable is exposed to both compressive and tensile stresses—such as underwater, in vertical shafts, or in soil with substantial elevation differences—cables with an internal steel‑wire armor should be selected.

8. Outer sheath of the power cord
The outer jacket is a structural component that protects the insulation of the power cable from environmental factors and corrosion. Its primary functions include enhancing the mechanical strength of the cable, providing resistance to chemical attack, preventing moisture ingress and water penetration, and inhibiting flame propagation. Depending on the specific requirements of the power cable, an extruder is used to directly extrude a plastic jacket over the conductor.