Top Background Image

FAQ

Frequently Asked Questions (FAQ)

Welcome to our Technical & Support FAQ. To help you find the information you need quickly, we have categorized our most common inquiries into four sections: General Knowledge, Advanced Engineering & Troubleshooting, Extreme Environment Solutions, and Customization & Ordering.

Part 1: General Product Knowledge

1. What are the common types of special cables?

Our special cable portfolio includes:

  • High-Temperature Cables: Resistant to -60°C to 200°C+.

  • Flame-Retardant & LSZH Cables: Low smoke zero halogen, flame retardant grades V0/V1.

  • Shielded Cables: Anti-EMI/RFI for signal integrity.

  • Waterproof Cables: IP67/IP68 rated for submerged applications.

  • Explosion-Proof Cables: Spark and corrosion-resistant.

  • Drag Chain Cables: Highly flexible and abrasion-resistant for dynamic automation.

2. What are the core differences between special cables and ordinary cables?

  • Performance: Special cables withstand extreme environments (high heat, deep sea, strong EMI, radiation) and offer higher safety ratings. Ordinary cables only meet conventional electrical transmission needs.

  • Materials: We utilize advanced materials like fluoroplastics (PTFE/FEP), silicone rubber, and tinned copper, whereas ordinary cables rely on standard PVC and PE.

  • Applications: Specifically engineered for aerospace, marine, nuclear fusion, new energy, and heavy industry, rather than standard residential or commercial buildings.

3. What are the temperature ranges and applications for High-Temperature Cables?

  • Silicone Rubber: -60°C to 200°C.

  • Fluoroplastics: -200°C to 300°C.

  • Applications: Metallurgy, industrial kilns, aerospace, and new energy battery compartments.

4. What are the core advantages of Low Smoke Zero Halogen (LSZH) cables?

During a fire, LSZH cables release minimal smoke (transmittance ≥ 60%) and no toxic halogens (Cl⁻/Br⁻ content < 50mg/kg). This significantly reduces toxicity and corrosive gases, protecting both human life and sensitive electronic equipment. They are essential for subways, hospitals, data centers, and high-rise buildings.

5. How can I judge the quality of a special cable?

Look for four key indicators:

  1. Material Precision: Insulation layer thickness matches standards (±0.1mm); shielding coverage is ≥ 85%.

  2. Test Reports: Must pass extreme tests like temperature cycling (-40°C to 150°C for 1000 cycles) and maintain high insulation resistance (≥ 100MΩ·km).

  3. Appearance: Clear, durable surface printing (model/specs/certifications) with no bulges or scratches.

  4. Certifications: Compliance with global standards such as UL (USA), CE (EU), or CCC (China).

Part 2: Engineering & Technical Troubleshooting

6. How do you solve signal jitter in high-speed data cables (10Gbps+)?

Potential Causes: High dielectric loss (tanδ), uneven conductor twisting causing impedance fluctuations, or insufficient shielding.Our Solutions: * Utilize FEP or foamed PE low-loss dielectrics (tanδ < 0.001@1GHz).

  • Implement precise twisting technology (pitch error ≤ ±2%).

  • Use double-layer shielding (Al-foil + tinned copper mesh, coverage ≥ 98%).

  • Calibrate impedance consistency (Z0 = 100 ± 5Ω) using a Vector Network Analyzer (VNA).

7. How do you improve phase stability during temperature cycling (-40°C to 85°C)?

When phase change exceeds ±30°/m, we optimize material and structural matching:

  • Use low-CTE dielectrics (e.g., PTFE with ceramic micro-powder, reducing CTE to 50×10⁻⁶/°C).

  • Utilize Invar (Ni36) or titanium alloy for the inner conductor to match the thermal expansion of the outer shield.

  • Apply spiral winding shielding instead of direct welding to reduce stress concentration.

8. Why do aerospace cables experience core breakage during vibration testing, and how is it fixed?

Causes: Conductor wire diameter is too large (>0.2mm), or adhesion between insulation and conductor is too rigid.Our Solutions: * Use ultra-fine stranded copper (7×37 strands, 0.08mm diameter) for maximum flexibility.

  • Extrude a 0.05mm polyimide film buffer layer.

  • Use vibration-resistant fluororubber to pass IEC 60068-2-6 tests (2000Hz for 8 hours without breakage).

9. How do you eliminate electromagnetic interference in MRI cables (3T magnetic fields)?

We utilize a "Full Shielding + Magnetic Isolation" design:

  • Shielding: Silver-plated copper tape (≥90% overlap) + high-permeability permalloy tape (μ≥8000).

  • Structure: Twisted-pair configurations (pitch 5-10mm) to reduce loop area (≤0.1cm²).

  • Hardware: Titanium alloy (non-magnetic) connectors to prevent eddy currents, combined with multi-point grounding (≤0.5Ω).

10. How do you choose oil-resistant cables for CNC machines using harsh cutting fluids?

Selection depends strictly on the oil composition:

  • Mineral Oils: Chloroprene rubber (CR) insulation (swelling ≤15%, IEC 60811-2-1).

  • Synthetic/Ester Oils: HNBR or Perfluoroelastomer (FFKM) (swelling ≤8%).

  • High-Temp Oil (>120°C): XLPE insulation for superior anti-aging compared to rubber.

11. How do you prevent insulation cracking when laying PTFE cables in cold environments (-40°C)?

  • Preheat: Gently warm the cable with a hot air gun (50-60°C) for 10-15 minutes prior to installation.

  • Bending Limits: Ensure bending radius is ≥ 10x OD (static) or 15x OD (dynamic). Never bend past 90 degrees.

  • Installation: Use toothless pulleys and keep traction force under 15% of breaking strength.

12. How do you fix High VSWR (>1.2@18GHz) in RF Coaxial Cables during production?

We strictly control process variables:

  • Monitor inner conductor roundness with laser micrometers (tolerance ≤ 0.005mm).

  • Calibrate extrusion dies to ensure dielectric concentricity (eccentricity error < 2%).

  • Maintain stable laying tension (±2%) to prevent dielectric stretching.

Part 3: Extreme Environment Solutions (Marine, Deep Sea & Nuclear)

13. What is the difference between Waterproof Cables and Submarine Cables?

  • Waterproof Cables: Designed for damp, submerged, or localized high-pressure environments (e.g., ROVs, underwater cameras, pool sensors). They focus on IP68 sealing and flexibility.

  • Submarine Cables: Massive, heavily armored infrastructure cables used for long-distance seabed power and telecommunication transmission between landmasses.

14. How do you prevent ROV cable water leakage after repeated dynamic movement?

We implement a robust "Radial + Axial" sealing strategy:

  • Radial: Hot melt adhesive paired with semi-conductive water-blocking tape (≥300% expansion).

  • Axial: Butyl rubber sealing paste filling conductor gaps, wrapped in steel tape armor.

  • Dynamic Connectors: O-ring (fluororubber) + wedge seals with a precisely controlled 20-30% compression rate.

15. How do zero-buoyancy ROV cables maintain exact buoyancy (±3%)?

We use precise material and structural calculations:

  • Extrude low-density PE foamed sheaths (controlling nitrogen injection).

  • Embed hollow glass microspheres (density 0.2g/cm³) into the cable core.

  • Strictly calculate the buoyancy-to-mass ratio and verify via 24-hour water tank suspension tests.

16. What makes Nuclear Fusion Cables unique?

Used in tokamak devices, these highly specialized superconducting cables transmit power for massive magnetic confinement systems. They must withstand extreme neutron radiation and high temperatures without degrading.

17. How do you improve the radiation resistance of nuclear cables?

  • Insulation: Irradiation-crosslinked PE (XLPE) combined with a high-purity mica tape composite (radiation resistance ≥2000kGy).

  • Conductor: Nickel-based alloys (Inconel 600) with a 5μm nickel coating to prevent oxidation.

  • Jacket: PEEK material for exceptional strength retention post-radiation.

Part 4: Customization, Lead Times & Ordering

18. What information do I need to provide to customize a special cable?

To ensure precise engineering, please provide:

  1. Application: (e.g., aerospace engine, deep-sea ROV).

  2. Electrical Specs: Voltage, current, signal type, frequency.

  3. Environment: Temp range, chemical exposure, EMI intensity.

  4. Mechanical Specs: Bending radius (static/dynamic), tensile strength.

  5. Structure: Conductor size, shielding preference, outer jacket material.

  6. Installation: Fixed, drag chain, buried, or submerged.

  7. Certifications: UL, CE, CCC, IEC, etc.

19. If I only know I need a cable for "6000 meters deep sea," how do we proceed?

Our engineering team will help you refine the technical parameters. For a 6000m depth, we typically specify:

  • Insulation resistance and high-voltage AC/DC ratings.

  • Dynamic tensile strength (≥ 50kN) and API 17E standard armor (316L stainless steel).

  • Protection against 3.5% salinity and microbial corrosion.

20. How can we shorten the lead time for custom cables?

Standard lead times depend on material sourcing and testing. To expedite:

  • We pre-stock common specialized materials (copper, standard dielectrics).

  • We utilize modular shielding and armor designs.

  • We run parallel material procurement and sample testing once the blueprint is approved.

21. Can you provide product samples? Are they free?

Yes, we fully support prototyping.

  • Low-Value / Standard Items: We can provide short sample lengths for free (shipping costs apply).

  • High-Value / Custom Engineering: Due to the complex setup costs and expensive raw materials involved, custom samples require a sample fee. This fee is often credited towards your first bulk order.


Quick Inquiry