How to increase the service life of the cable?

After several years of rapid development, China's mining cable industry has grown significantly in scale. However, the sector is now facing a major challenge: overcapacity. Production capacity has far exceeded actual demand, with supply surpassing what was initially forecasted for this year. This imbalance has led to intense competition and pressure on companies to improve their product quality and technological sophistication. One of the key issues is low-level redundant construction. The wire and cable industry has not adequately focused on optimizing its product structure, resulting in an oversupply of basic products and a lack of high-end offerings. For instance, bare wire production accounts for nearly 20% of total output in China, while developed countries only produce around 10%. Within bare wires, overhead lines and common aluminum conductor steel-reinforced (ACSR) cables dominate, indicating a lack of innovation and diversification. Another pressing problem is low economic efficiency. Over 700 enterprises in the industry are operating at a loss, contributing to nearly a quarter of the total losses in the sector. In 1991, the industry’s tax rate on sales income was 11.7%, but by 1995, it had dropped to just 5%. As efficiency declined, the number of loss-making companies increased, and overall financial conditions became tighter. The average debt-to-equity ratio reached as high as 70%, signaling serious liquidity concerns. Additionally, the industry has expanded too quickly, with total capacity more than double the actual demand. Forecasts for major products in 2000 showed that production capacity far outstripped expected demand, creating a significant gap between supply and consumption. During use, the local bending radius of shearer cables is often much smaller than that of standard cables. These cables are frequently subjected to long-term stress from excessive bending, stretching, and other mechanical forces. Moreover, the cross-sectional area of the control core is much smaller than that of the main conductor, leading to frequent breakage of the control core. To address these issues, several improvements can be made: 1. Enhance the flexibility of shearer cables used in coal mines to better suit harsh working environments. 2. Increase the relative slippage of the control wire core to reduce wear and tear. 3. Improve the strength of shearer cable conductors to withstand heavy usage. 4. Change the original bundle-twisted structure of the conductor to a regular twisted one, which enhances bending performance. Additionally, braiding wire around the conductor can increase its strength. 5. Use tinned copper wire for the control core and incorporate braided weaving, which can significantly improve durability and performance. These adjustments will not only improve the reliability of mining cables but also help the industry move toward higher value-added products, reducing overcapacity and increasing competitiveness.

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