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**Fully-Automatic Cable Thermal Repairing Machine**
The fully-automatic cable thermal repairing machine is specifically designed for the repair and pressing of cables used in coal mines, iron ore extraction, drilling, and well construction. This advanced equipment is constructed from high-quality alloy aluminum, ensuring durability and stability. It features a hydraulic clamping system that allows precise temperature control, making the operation more efficient, energy-saving, and reliable. The machine offers high work efficiency, easy maintenance, and ensures the quality of the repaired cables. After repair, the cables appear smooth, firm, and well-sealed, with excellent pressure resistance. It is considered one of the most advanced thermal repair devices in China.
**Structure Overview**
The fully automatic cable thermal repair machine consists of several key components: a sturdy frame, an electrical system, a hydraulic system, and an instrument control panel. The hydraulic system includes hydraulic cylinders, pistons, valves, and pressure rods, which are responsible for adjusting the mold pressure to meet the requirements of the heating and bonding process. The frame is made of welded steel sections and includes a running mechanism, toolbox, and counterweight, forming a stable and mobile platform. The electrical heating system is installed separately but controlled uniformly, featuring constant temperature regulation and indicator lights for better performance control.
**Detecting Cable Breakage**
This process is specifically designed for the repair of rubber-sheathed cables. The first step involves conducting a pressure test on the cable. If the voltage does not meet the required standard, it indicates that the insulation layer may be damaged and needs repair before use. In cases where leakage is detected during operation, a direct pressure test can be performed, followed by immediate repair.
Next, one end of the cable is placed in the junction box of a cable dryer and inflated. If there is a noticeable "hissing" sound, it indicates damage, and the affected area should be marked for repair. If no sound is detected, soapy water can be applied to the suspected area. If bubbles form, it means there is a leak, and that section must be repaired. This process is repeated until all leaks are addressed and the cable is fully restored.
**Cable Repair Methods**
There are three main methods for repairing cables:
**1. Partial Repair**
When the cable has small holes or damages covered by rubber, an electric knife can be used to cut around the damaged area. A wooden tool or hair-pinning machine can be used to roughen the surface. Apply adhesive to the damaged part, then cover it with hot-tapping tape. Depending on the depth of the damage, two to three layers of tape should be applied, each larger than the previous, until the surface is smoother than the original cable. Select a mold matching the cable type, place a pre-cut separator on the top of the mold, and position the damaged area in the center of the mold.
**2. Full-Circle Repair**
If the rubber sheath is severely damaged but the core remains intact, a full-circle repair method can be used. Remove the damaged rubber sheath completely, cut the tape into a conical shape, and use a mandrel or wool hair machine to prepare the surface. Apply mortar at the joint, then wrap the tape around the cable. The number of wraps depends on the thickness of the cable, but it should be slightly thicker than the original. Place the joint in the middle of the mold after covering the inside with a pre-cut insulation membrane.
**3. Splicing Repair**
Splicing is used when the cable is completely broken or the core is mostly damaged. Cut both ends of the cable at an angle, bend the core heads into an umbrella shape, and align the longest core on one side with the shortest on the other. Ensure the color of the core sheaths matches, and strip 25mm of the outer skin from each core, exposing 25mm of copper wire. Choose a red copper tube with the same cross-sectional area as the core, insert the cores into the tube, and clamp both ends using a hydraulic press to secure the connection firmly. Repeat this for all cores, match them by color, wrap the exposed parts, insert the bundle into the mold, and apply heat to complete the repair.
Super alloy castings refer to the production of components using superalloys—metal alloys designed to withstand high stresses, high temperatures, and often corrosive environments without losing their mechanical strength or stability. These materials typically include combinations of nickel, cobalt, chromium, and iron, and are known for their exceptional heat resistance, corrosion resistance, and strength at elevated temperatures.
Super alloy castings are crafted through processes like Investment Casting, which is ideal for achieving the complex shapes and high precision required in industries where superalloys are crucial. These industries often include aerospace, for turbine blades and jet engine parts; power generation, for boiler parts and gas turbine components; and the chemical industry, where equipment must resist corrosion by harsh chemicals at high temperatures.
These casting processes involve careful control of temperatures and material composition to ensure that the superalloys’ unique properties—such as resistance to thermal creep deformation, surface stability, and resistance to oxidation—are fully realized in the final product.