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Welding Machine Cable
Short Description:
Welding Machine Cables are suitable for the secondary connection of welding machines with an AC voltage not exceeding 200 V and pulsating DC with a peak of 400 V. The maximum operating temperature of the cable is 65C. These cables exhibit good flexibility.The sheath is made of natural rubber or a neoprene rubber compound, making it suitable for various applications. The product features weather resistance, softness, light weight, and excellent bending performance.
Product Introduction
Selection Guidelines
Classification standard
Installation and Maintenance Precautions
| Dimension | Detailed Description |
|---|---|
| Product Definition | Commonly known as welding torch cable/ground cable, it is a special type of flexible industrial cable specially developed for arc welding machines. It is divided into two core categories: primary side input cable (the connection line between the welding machine and the grid power supply) and secondary side output cable (welding torch cable/ground cable, the connection line between the welding machine and the welding torch/workpiece). It is the core basic component that carries high current and ensures the safety of welding operations in the welding system. |
| Core Materials | 1. Conductor: The core adopts high-purity oxygen-free copper/tinned copper, and the multi-strand ultra-fine flexible conductor stranding structure is preferred to ensure the high flexibility, bending resistance and high current carrying capacity of the cable;2. Insulation/Sheath: The mainstream materials are Natural Rubber (NR), Chloroprene Rubber (CR), Nitrile Butadiene Rubber (NBR), low smoke zero halogen flame retardant rubber, which can be matched with special modified materials for oil resistance, flame retardancy, weather resistance and high temperature resistance according to working conditions;3. Supporting structure: It can be matched with copper mesh shielding, steel tape/steel wire armouring, flame retardant and fire resistant layer, water blocking and waterproof structure to meet the protection requirements of special working conditions. |
| Core Characteristics | 1. High flexibility and elasticity: The rubber material has a low elastic modulus and excellent softness, which can be laid with an extremely small bending radius, and has excellent bending fatigue resistance. It can be dragged and bent repeatedly without fracture, which perfectly adapts to the high-frequency moving conditions of welding operations;2. High wear and tear resistance: The sheath has high mechanical strength, and its wear and tear resistance is far superior to ordinary PVC cables. It can withstand dragging, rolling and friction during welding operations, and resist the high temperature impact of welding spatter;3. High current carrying capacity: High-purity copper conductor + optimized stranding structure, with sufficient current carrying redundancy, which can stably carry the high current impact of welding operations without obvious heating and voltage drop;4. Flame retardant and high temperature resistance: It can be matched with a high flame retardant low smoke zero halogen sheath, which does not drip or release toxic gases during combustion, and can withstand the instantaneous high temperature of welding spatter without melting or damage to the sheath;5. Oil and corrosion resistance: Synthetic rubber materials can withstand corrosive media such as mineral oil, hydraulic oil, acid and alkali solutions, and organic solvents, adapting to oil/corrosion environments such as workshops, construction sites, and ships;6. Aging resistance, waterproof and moisture resistance: UV resistance, ozone resistance, rain and snow resistance, heat and humidity resistance, which can operate stably in outdoor and humid environments for a long time without attenuation of insulation performance. |
| National/International Implementation Standards | Core National Standard: GB/T 5013.6-2008 Rubber Insulated Cables for Rated Voltages up to and Including 450/750V - Part 6: Welding Machine Cables;Supporting Standards: GB/T 12706 Series Standards for Extruded Insulated Power Cables, GB/T 19666 General Rules for Flame Retardant and Fire Resistant Wires and Cables, GB/T 2951 General Test Methods for Cable Insulation and Sheath Materials, JB/T 8734 PVC Insulated Shielded Wires and Flexible Cords for Rated Voltages up to and Including 450/750V;International Standards: IEC 60245 Rubber Insulated Cables, UL 62 Safety Standard for Flexible Cords and Cables. |
| Core Application Scenarios | 1. General industrial scenarios: Various arc welding, gas shielded welding, argon arc welding operations in machinery processing workshops, steel structure factories, automobile manufacturing plants, and equipment maintenance workshops;2. Building construction scenarios: On-site welding, road and bridge construction, steel structure installation for outdoor mobile welding operations;3. Ship and marine scenarios: Welding operations for shipbuilding, offshore platforms, port terminals, adapting to seawater, oil pollution, and high humidity environments;4. Underground mine scenarios: Welding operations in coal mines and metal mines, which need to be matched with explosion-proof and flame retardant special models;5. Precision welding scenarios: Precision welding operations in electronics, medical treatment, aerospace, which need to be matched with high flexibility, low smoke zero halogen special models. |
| Model Selection Module | Core Points | Detailed Description and Red Line Requirements |
|---|---|---|
| Core Red Line Principles for Model Selection | Compliance First | 1. All model selection must comply with the core national standard GB/T 5013.6-2008 for welding machine cables. For special scenarios such as coal mines, fire protection, and ships, compliant products with corresponding mandatory certifications such as MA/3C/CCS/flame retardant and fire resistant must be selected;2. Non-standard products without test reports and certification are strictly prohibited, especially in high current, outdoor, and explosion-proof scenarios, which must ensure that the current carrying capacity, flame retardancy, and wear resistance all meet the standards;3. The rated voltage, current carrying capacity, temperature resistance grade, and flame retardant grade must be higher than the maximum requirements of the actual application scenario. Low-specification models are strictly prohibited from being used beyond their applicable scenarios. |
| Scenario Matching | 1. Fully adapt to the welding current, moving frequency, environmental medium, laying method, mechanical external force, and safety protection requirements of the application scenario;2. For outdoor construction scenarios, weatherproof and waterproof models must be selected; for high oil pollution scenarios, oil resistant nitrile/chloroprene rubber models must be selected; for automated/robotic welding scenarios, high flexibility drag chain models must be selected; for underground coal mine scenarios, explosion-proof and flame retardant models must be selected;3. For scenarios with mechanical rolling and dragging risks, armoured structure must be selected; for high-frequency moving scenarios, multi-strand ultra-fine flexible conductor structure must be selected; for high drop vertical laying scenarios, steel wire armoured structure must be selected; for signal transmission scenarios, shielded structure must be selected. | |
| Performance Adaptation | 1. The current carrying capacity, wear and tear resistance, insulation performance, mechanical performance, oil and corrosion resistance must fully meet the actual welding operation requirements, with a 10%~20% redundancy reserved;2. Operation beyond the rated voltage, long-term operating temperature, minimum bending radius, and current carrying capacity is strictly prohibited;3. Take into account the economy and construction convenience, give priority to general-purpose models, and avoid excessive customization that leads to difficulties in later operation and maintenance. | |
| Core Parameter Selection | Material Selection | 1. Conventional indoor welding scenarios: priority is given to natural rubber/chloroprene rubber material, with good elasticity, wear and tear resistance, moderate cost, and strong versatility;2. Outdoor/weatherproof/waterproof scenarios: chloroprene rubber/chlorosulfonated polyethylene material must be selected, with excellent ozone resistance, UV resistance and waterproof performance, which is the first choice for outdoor scenarios;3. High oil pollution/strong corrosion scenarios: priority is given to nitrile rubber/chloroprene rubber material, with outstanding oil resistance, acid and alkali resistance, and corrosion resistance;4. Automated/robotic/high flexibility scenarios: high tear resistance chloroprene rubber/silicone rubber material must be selected, with the best high flexibility, bending resistance and wear resistance;5. Coal mine/fire protection/high safety scenarios: low smoke zero halogen flame retardant rubber material must be selected, with flame retardant grade ≥ Class B, non-flame retardant, high smoke and toxic materials are strictly prohibited;6. Red line requirement: The long-term allowable operating temperature of the material must be higher than the maximum ambient temperature of the scenario + conductor operating temperature rise, with a safety redundancy of more than 20℃ reserved. |
| Conductor Specification and Current Carrying Capacity Selection | 1. Conductor material: high-purity oxygen-free copper conductor is selected for conventional scenarios, and tinned copper conductor is selected for high flexibility/high humidity/outdoor scenarios to improve oxidation and corrosion resistance;2. Conductor cross section and current carrying capacity matching (core):① Secondary side welding torch cable: 10mm² for 50A welding current, 16mm² for 100A, 25mm² for 200A, 35mm² for 300A, 50mm² for 400A, 70mm² for 500A;② Primary side input cable: 1.5mm² for load within 10A, 2.5mm² for 10A~16A, 4mm² for 16A~25A, 6mm² for 25A~32A, 10mm² for 32A~50A;3. Current carrying capacity verification: According to the laying method, ambient temperature, and number of parallel cables, verify that the allowable current carrying capacity of the cable ≥ the actual maximum welding current, with a redundancy of more than 10% reserved. For high current and long-distance transmission scenarios, the cross section must be increased to avoid excessive voltage drop;4. Conductor structure: 7-strand hard conductor is selected for fixed laying, multi-strand ultra-fine flexible conductor must be selected for high-frequency moving/flexible scenarios, and high flexibility stranded flexible conductor must be selected for drag chain/robot scenarios to ensure bending life. | |
| Structure Selection | 1. Armouring structure: For outdoor direct burial, pipe laying, scenarios with mechanical rolling and dragging risks, steel tape/steel wire armouring structure must be selected; for high drop, vertical laying, scenarios with large tensile force, steel wire armouring structure must be selected to improve tensile and anti-falling performance;2. Shielding structure: For automated welding, precision welding, and electromagnetic interference scenarios, copper mesh/tinned copper tape shielding structure must be selected, with shielding coverage ≥85%, to avoid interference of welding current on surrounding equipment;3. Waterproof structure: For underwater welding, humid, water spraying, outdoor rain and snow scenarios, radial water blocking tape + waterproof sealing sheath + axial waterproof plug composite structure must be selected, with waterproof grade ≥IPX7, and must reach IPX8 for underwater scenarios;4. Flexible structure: For drag chain, robot, high-frequency moving bending scenarios, multi-strand ultra-fine flexible conductor + high tear resistant rubber insulation sheath composite structure must be selected, with the minimum bending radius up to 5 times the cable outer diameter, and bending life ≥5 million times;5. Flame retardant structure: For coal mine, fire protection, indoor confined space scenarios, high flame retardant low smoke zero halogen sheath + fire resistant mica tape composite structure must be selected to ensure power supply safety in fire scenarios. | |
| Voltage Grade Selection | 1. Primary side input line: priority is given to 450/750V rated voltage, with strong versatility and complete accessory matching, which is fully suitable for 220V/380V grid power supply;2. Secondary side output line: 100V, 200V, 300V, 500V rated voltage is selected according to the welding machine output voltage, and 300V/500V general-purpose models are preferred, which are suitable for the output voltage of most welding machines;3. Red line requirement: The rated voltage of the cable must be higher than the maximum input/output voltage of the welding machine, and operation beyond the rated voltage is strictly prohibited. | |
| Scenario Adaptation Verification | Environmental Parameter Verification | 1. Temperature verification: confirm that the long-term allowable operating temperature of the cable ≥ the maximum ambient temperature of the scenario + conductor operating temperature rise, and for low temperature scenarios, confirm that the minimum allowable operating temperature of the cable ≤ the historical extreme minimum temperature of the scenario, with a safety redundancy of more than 10℃ reserved;2. Corrosive medium verification: confirm that the corrosion resistance of the cable insulation sheath material fully matches the corrosive media such as oil stain, acid and alkali, organic solvent, seawater in the environment, and ordinary natural rubber materials are strictly prohibited in strong corrosion scenarios;3. Weather resistance verification: for long-term outdoor laying, chloroprene rubber/CSM materials with UV resistance, ozone resistance and salt spray resistance must be selected, and ordinary indoor cables are strictly prohibited from being replaced;4. Flame retardant safety verification: select cables of corresponding flame retardant/fire resistance grade according to the fire safety requirements of the scenario. Non-flame retardant, high smoke and toxic cables are strictly prohibited in indoor, coal mine and fire protection scenarios;5. Waterproof verification: for humid, water spraying, underwater scenarios, it must be confirmed that the waterproof grade of the cable matches the scenario requirements, and non-waterproof cables are strictly prohibited from being replaced. |
| Laying Parameter Verification | 1. Bending radius verification: confirm that the minimum allowable bending radius of the cable ≤ the actual laying bending radius. The minimum bending radius for fixed laying is ≥10 times the cable outer diameter, for mobile laying is ≥15 times the cable outer diameter, and for drag chain/high flexibility scenarios is ≥5 times the cable outer diameter. Laying with excessive small bending radius is strictly prohibited to avoid damage to the insulation layer and conductor core breakage;2. Laying space verification: confirm that the outer diameter and structure of the cable fully match the laying drag chain, pipeline, cable tray and installation space to avoid installation failure;3. Construction adaptability verification: confirm that the flexibility and structure of the cable adapt to the construction technology of the scenario, such as drag chain installation, equipment wiring, outdoor direct burial, etc., to avoid cable damage during construction;4. Tensile resistance verification: for high drop, vertical laying, long-span laying scenarios, it must be confirmed that the tensile resistance of the cable ≥ the actual maximum axial tensile force, and operation beyond the tensile force is strictly prohibited. | |
| Electrical Performance Verification | 1. Current carrying capacity verification: according to the laying method, ambient temperature, and number of parallel cables, verify that the allowable current carrying capacity of the cable ≥ the actual maximum welding current, with a redundancy of more than 10% reserved;2. Voltage drop verification: verify that the line voltage drop of the cable ≤ the maximum allowable voltage drop of the system. For long-distance transmission, the conductor cross section must be increased to avoid insufficient welding voltage;3. Short circuit current verification: verify that the short circuit thermal stable current of the cable ≥ the maximum short circuit current of the system to ensure that the cable will not be broken down in short circuit scenarios;4. Anti-interference performance verification: for automated/precision welding scenarios, the shielding performance and anti-electromagnetic interference capability of the cable must be verified to ensure the stable operation of the welding control system. | |
| Compliance and Supporting Selection | Certification and Test Confirmation | 1. It must be confirmed that the target product has a complete factory test report, and the test items cover core indicators such as current carrying capacity, wear and tear resistance, oil and corrosion resistance, electrical performance, mechanical performance, flame retardant performance, especially bending life test for high flexibility scenarios;2. For special scenarios such as coal mines, fire protection, ships, it must be confirmed that the product has corresponding mandatory certifications such as MA/3C/CCS/flame retardant and fire resistance, the certification is within the validity period, and the certification scope covers the selected specifications;3. Non-standard products without certification and test reports are strictly prohibited, especially in high risk and high current scenarios, which must ensure that the product performance meets the standards. |
| Supporting Accessory Selection | 1. Special accessories that fully match the voltage grade, specification, material and waterproof grade of the cable must be selected simultaneously, including welding wiring terminals, welding torch connectors, ground clamps, junction boxes, penetration pipes, fixing parts, etc.;2. For high flame retardant/fire resistant scenarios, supporting accessories of corresponding flame retardant/fire resistant grade must be selected to ensure the safety performance matching of the whole link;3. For shielded cables, suitable shielded connectors and grounding terminals must be selected to ensure reliable grounding of the shielding layer and up-to-standard anti-interference effect;4. For underwater/high humidity scenarios, special sealing accessories with matching waterproof grade must be selected to ensure the waterproof sealing performance of the whole link. | |
| Operation and Maintenance Supporting Confirmation | 1. Priority is given to models with large market holdings and strong versatility to ensure convenient later accessory supply and operation and maintenance replacement;2. Excessively customized non-standard models are avoided to prevent excessive later operation and maintenance costs and replacement difficulties;3. It is confirmed that the manufacturer has complete after-sales technical support and on-site construction guidance services, especially for high flexibility, explosion-proof, outdoor scenarios, to ensure the correct installation and use of the cable. |
| Classification Dimension | Sub-category | Core Definition and Characteristics | Typical Model Examples |
|---|---|---|---|
| By National Standard Product Series (Core Classification) | General Purpose Welding Machine Cable | The core basic category of the national standard, with natural rubber insulation and sheath, high flexibility, wear resistance, moderate cost, suitable for conventional welding operations in indoor workshops, and the most widely used general-purpose category | YH, YH-1, YH-2 |
| Oil Resistant Welding Machine Cable | Chloroprene rubber/nitrile butadiene rubber insulation and sheath, with excellent oil resistance, corrosion resistance and aging resistance, suitable for welding operations in oil pollution environments such as workshops, construction sites, and ships | YHF, YH-F, YH-NBR | |
| Outdoor Weather Resistant Welding Machine Cable | Chloroprene rubber/chlorosulfonated polyethylene insulation and sheath, UV resistance, ozone resistance, rain and snow resistance, waterproof and moisture resistance, suitable for outdoor construction and open-air welding operations | YH-W, YH-WF, YH-CSM | |
| High Flexibility Drag Chain Welding Machine Cable | Composite structure of multi-strand ultra-fine flexible conductor + high tear resistant rubber insulation and sheath, which can achieve more than 5 million times of repeated bending without fracture, and the minimum bending radius can reach 5 times the cable outer diameter, suitable for automated welding, robotic welding, and drag chain systems | YH-X, YH-TR, YH-Robot | |
| Coal Mine Explosion-proof Welding Machine Cable | Low smoke zero halogen flame retardant rubber insulation and sheath, explosion-proof, flame retardant, anti-static, in line with coal mine safety standards, suitable for welding operations in underground coal mines and high gas environments | MHY, MHYV, YH-MA | |
| Low Smoke Zero Halogen Flame Retardant Welding Machine Cable | Low smoke zero halogen flame retardant rubber insulation and sheath, no dripping, low smoke and non-toxic, no corrosive gas release during combustion, flame retardant grade up to Class A of GB 31247, suitable for indoor, confined spaces, and high safety requirement welding operations | WDZ-YH, WDZ-YHF, ZA-YH | |
| By Insulation Sheath Material | Natural Rubber (NR) Welding Machine Cable | Uses natural rubber as insulation and sheath material, with excellent elasticity, good flexibility, high mechanical strength and moderate cost. It is the basic material for general-purpose welding machine cables, with long-term operating temperature -50℃~65℃ | YH, YH-1 |
| Chloroprene Rubber (CR) Welding Machine Cable | Uses chloroprene rubber as insulation and sheath material, with excellent weather resistance, ozone resistance, waterproof, flame retardant and oil resistance, long-term operating temperature -40℃~80℃. It is the main material for outdoor and oil resistant scenarios | YHF, YH-W, YH-CR | |
| Nitrile Butadiene Rubber (NBR) Welding Machine Cable | Uses nitrile butadiene rubber as insulation and sheath material, with outstanding oil resistance, wear resistance and tear resistance, resistant to mineral oils such as gasoline, diesel and hydraulic oil, long-term operating temperature -40℃~70℃, suitable for high oil pollution scenarios | YH-NBR, YH-F, YHF-N | |
| Low Smoke Zero Halogen Flame Retardant Rubber Welding Machine Cable | Uses low smoke zero halogen flame retardant rubber as insulation and sheath material, with high flame retardancy, low smoke and non-toxicity, no corrosive gas release, suitable for high safety requirement scenarios | WDZ-YH, ZA-YH, MHY | |
| Silicone Rubber Welding Machine Cable | Uses silicone rubber as insulation and sheath material, with the best high and low temperature resistance, long-term operating temperature -60℃~180℃, outstanding flexibility, insulation and weather resistance, suitable for extreme high and low temperature and precision welding scenarios | YH-G, YH-Si, YH-180 | |
| By Structural Characteristics | Non-armoured General Purpose Welding Machine Cable | No metal armouring layer, simple structure, convenient laying, low cost and excellent flexibility, suitable for indoor workshops and conventional welding scenarios without mechanical external impact | YH, YHF, YH-W |
| Shielded Welding Machine Cable | Added copper mesh/tinned copper tape shielding layer, with extremely strong anti-electromagnetic interference and anti-radio frequency interference capability, which can avoid the interference of welding current on surrounding precision equipment and control systems, suitable for automated welding and precision welding scenarios | YH-P, YH-PB, YH-Robot-P | |
| Armoured Welding Machine Cable | Added steel tape/steel wire/aluminum-plastic composite tape armouring layer, with excellent mechanical impact, compression, tensile and puncture resistance, high protection level, suitable for outdoor direct burial, pipe laying, scenarios with mechanical rolling and dragging risks | YH22, YHF22, YH32 (Steel Wire Armoured) | |
| Waterproof Submersible Welding Machine Cable | Matched with radial water blocking tape + waterproof sealing sheath + axial waterproof plug composite structure, with waterproof grade up to IPX8, water pressure resistance, corrosion resistance and microbial resistance, suitable for underwater welding, humid, water spraying, swimming pool/ship welding scenarios | YH-S, YH-SUB, YH-WS | |
| Flame Retardant and Fire Resistant Welding Machine Cable | Matched with high flame retardant low smoke zero halogen sheath + fire resistant mica tape composite structure, with flame retardant grade up to Class A of GB 31247, which can maintain normal power supply for more than 90 minutes in 950℃ flame, suitable for fire emergency and high safety requirement welding scenarios | ZA-YH, NH-YH, WDZ-YH-N | |
| Flat Welding Machine Cable | Adopts flat structure design, multi-core wires arranged in parallel, thin thickness, good flexibility, can be laid on the ground, suitable for automated welding, robotic welding, scenarios with limited installation space | YH-B, YHF-B, YH-TR-B | |
| By Rated Voltage/Current Grade | Primary Side Input Cable | Rated voltage 450/750V, 0.6/1kV, suitable for the connection between the welding machine and the grid power supply, carrying the input current of the welding machine, conventional current grade 10A~100A | YH-450/750V, YH-0.6/1kV, YHF-450V |
| Secondary Side Output Cable (Welding Torch/Ground Cable) | Rated voltage 100V, 200V, 300V, 500V, suitable for the connection between the welding machine and the welding torch/workpiece, carrying the high welding current, conventional current grade 50A~500A+, the core category of welding machine cables | YH-100V, YH-200V, YHF-300V, YH-500A | |
| By Application Scenario | General Industrial Welding Machine Cable | Designed for conventional welding operations in indoor workshops, with high flexibility, wear resistance and moderate cost, suitable for general scenarios such as manual arc welding and gas shielded welding | YH, YHF, YH-1 |
| Outdoor Construction Welding Machine Cable | Designed for outdoor construction sites and open-air welding operations, with weather resistance, UV resistance, waterproof, rolling resistance and low temperature resistance, suitable for building construction, road and bridge construction, steel structure installation scenarios | YH-W, YH-WF, YH-CSM | |
| Ship and Marine Welding Machine Cable | Designed for welding operations of ships and offshore platforms, with seawater corrosion resistance, oil resistance, waterproof, microbial resistance and flame retardancy, suitable for shipbuilding, port terminals, marine engineering scenarios | YH-MAR, YHF-MAR, YH-SUB | |
| Coal Mine Explosion-proof Welding Machine Cable | Designed for underground coal mine welding operations, with explosion-proof, flame retardant, anti-static, low smoke zero halogen, in line with coal mine safety standards, suitable for underground coal mine and metal mine scenarios | MHY, MHYV, YH-MA | |
| Automated Welding Welding Machine Cable | Designed for robotic welding and automated welding lines, with high flexibility, high bending resistance, fatigue resistance and excellent shielding performance, suitable for drag chain systems and robotic welding scenarios | YH-X, YH-TR, YH-Robot | |
| Precision Welding Welding Machine Cable | Designed for precision welding operations in electronics, medical treatment and aerospace, with low smoke zero halogen, high flexibility, low interference and high temperature resistance, suitable for confined spaces and high safety requirement scenarios | WDZ-YH, YH-G, YH-Si |
| Maintenance Level | Maintenance Items | Execution Cycle | Operation Standard | Abnormal Handling Method |
|---|---|---|---|---|
| Special Protection During Construction Phase (Core Pre-maintenance) | Cable Incoming Acceptance | When the cable enters the site | 1. Check the model specification, material, certification certificate and test report of the cable to confirm that it is consistent with the model selection requirements, with focus on checking the current carrying capacity, wear and tear resistance, flame retardant performance test report;2. Check the appearance of the cable, the sheath is free of damage, deformation, aging, bulging, the insulation layer is intact, and there is no trace of moisture, water ingress or frost cracking;3. Test the insulation resistance of the cable with a megohmmeter, the insulation resistance is ≥10MΩ·km, and there is no short circuit or open circuit;4. For cables used in high flexibility drag chain scenarios, the special test data of bending life and tear strength must be checked to ensure they meet the standards. | 1. If the cable model specification is inconsistent, the material does not match, without certification or core performance test report, it is strictly prohibited to enter the site for use, and must be returned and exchanged immediately;2. If the cable sheath is damaged, the insulation layer is damaged, moisture/water ingress or frost cracking is found, it is strictly prohibited to use, and must be replaced immediately;3. If the insulation resistance is not up to standard, short circuit or open circuit is found, it is strictly prohibited to use, and must be replaced immediately. |
| Protection During Construction | Throughout the construction period | 1. Before cable laying, check that the drag chain, trench, pipeline and cable tray of the laying path are free of sharp objects and burrs to avoid the cable being scratched or punctured during laying;2. During cable laying, it is strictly prohibited to bend, twist or drag the cable with an excessive small bending radius, and it is strictly prohibited to roll or step on the cable, especially the high-frequency moving part of the welding torch cable, to avoid damage to the insulation layer and conductor core breakage;3. When laying drag chain cables, it must be ensured that the cables are not twisted, tension-free and firmly fixed in the drag chain to avoid dragging and friction during operation;4. After the laying is completed, do a good job of waterproof plug and sealing treatment in time to avoid moisture and water ingress at the cable ends, and make identification marks for later operation and maintenance;5. For construction in low temperature environment, thermal insulation protection of the cable must be done well to avoid the cable being frozen and brittle during construction. | 1. If the cable sheath is damaged or the insulation layer is damaged during laying, stop the construction immediately, replace the damaged cable, and it is strictly prohibited to continue to use after repair;2. If the cable is bent or twisted with an excessive small bending radius, re-lay the cable in a standardized manner immediately, and test the insulation performance and conductor integrity to ensure no damage;3. If moisture, water ingress or frost damage is found at the cable ends, dry and seal them immediately, test the insulation resistance, and replace them immediately if unqualified. | |
| Daily Inspection (Operation Period) | Per Shift/Daily Operation Inspection | Before/after each welding operation | 1. Check that the sheath of the welding torch cable and ground cable is free of damage, aging, deformation, bulging, wear, the insulation layer is intact, no exposure, no trace of water ingress or moisture;2. Check that the welding torch connector, ground clamp, and wiring terminal are free of heating, sparking, looseness, oxidation, and erosion, and the connection is firm;3. Check that the cable laying state is free of looseness, falling, excessive bending, dragging, winding, twisting, no risk of being rolled by equipment or vehicles, and no trace of high temperature burn from welding spatter;4. Check that the cable operating environment is free of acid and alkali corrosion, oil stain, high temperature heat source, flammable and explosive media, and no potential safety hazards. | 1. If slight damage, aging or wear of the sheath is found, mark it immediately, arrange for professional personnel to repair it after power off, and do a good job of insulation protection;2. If exposed insulation layer, joint heating and sparking, or serious cable deformation/twisting are found, cut off the power and stop the machine immediately, continue to use is strictly prohibited, and arrange for professional personnel to test and replace;3. If the cable is rolled, excessively bent, dragged or jammed, cut off the power immediately, clear the obstacles, re-fix it in a standardized manner, test the insulation performance and conductor integrity of the cable, and replace it immediately if unqualified;4. If the cable is close to a high temperature heat source or corrosive medium leakage, clean and isolate it immediately, check the cable damage, replace it if necessary, and do a good job of protective measures. |
| Weekly Comprehensive Inspection | Once a week | 1. Conduct a comprehensive appearance inspection of the primary side input cable, secondary side welding torch cable/ground cable, focusing on the sheath wear and aging of joints, bending, dragging, and rolling parts;2. Check the fastening of all wiring terminals, connectors, and ground clamps, no looseness, oxidation, erosion, and the seal is intact;3. Check that the cable fixing and guiding devices are free of looseness, jamming, friction, and the drag chain runs smoothly;4. Check the insulation resistance of the cable, control cable ≥10MΩ·km, power cable ≥10MΩ·km, no short circuit or open circuit;5. Check the grounding continuity, grounding resistance ≤4Ω, no looseness or breakage. | 1. If the sheath wear exceeds 1/3 of the original thickness, replace the cable immediately to avoid insulation failure caused by sheath damage;2. If the joint is loose, oxidized or eroded, tighten it immediately after power off, replace the damaged terminal/connector, and ensure the connection is reliable;3. If the insulation resistance is lower than the standard value, check the cause immediately, test whether there is moisture, water ingress, damage, aging, and replace the cable if necessary;4. If the grounding resistance exceeds the standard or the grounding fails, repair it immediately to ensure reliable grounding and avoid electric shock risk. | |
| Regular Special Tests | Insulation Resistance and Grounding Continuity Test | Once a month | 1. In the power-off state, use a 500V megohmmeter to test the insulation resistance between the cable cores and between the cable core and the ground, control cable ≥10MΩ·km, low voltage power cable ≥10MΩ·km;2. Use a grounding resistance tester to test the grounding continuity of the cable shielding layer and grounding terminal, the grounding resistance value ≤4Ω, and the conduction resistance between the shielding layer and the grounding terminal ≤0.5Ω;3. The test environment temperature is 20℃±5℃, the relative humidity is ≤80%, and the cable must be fully discharged and dried before the test to ensure the accuracy of the test data. | 1. If the insulation resistance is lower than the standard value, check the cause immediately, test whether there is moisture, water ingress, damage, aging;2. If the insulation resistance drops by more than 30%, arrange for professional personnel to conduct a comprehensive test immediately, and replace the cable if necessary;3. If the insulation resistance is 0, cut off the power immediately, continue to use is strictly prohibited, check the short circuit point and replace the cable;4. If the grounding resistance exceeds the standard or the grounding fails, repair it immediately to ensure reliable grounding and avoid electric shock and electromagnetic interference risks. |
| Joint and Terminal Special Inspection | Once a month | 1. In the power-off state, check the sealing performance of the cable joints, terminals and connectors, no leakage, cracking, deformation, aging, icing, and the sealant is not invalid;2. Use an infrared thermometer to test the surface temperature of the joints, terminals and wiring terminals, no abnormal heating, the temperature difference with the cable body is ≤5℃, no local overheating;3. Check that the wiring terminals are free of looseness, oxidation, erosion, icing, the tightening torque meets the standard, and no discharge or sparking trace. | 1. If the joint seal fails, leaks, cracks or ices up, cut off the power and stop the machine immediately, re-do the sealing and waterproof treatment, and test the insulation performance;2. If abnormal heating or excessive temperature difference of the joint is found, check the cause immediately, test whether there is virtual connection, oxidation, overload, water ingress, and re-make the joint or replace the connector if necessary;3. If the wiring terminal is loose, eroded or iced up, tighten it immediately after power off, clear the icing, replace the damaged terminal, and ensure the connection is reliable. | |
| Wear and Bending Life Special Test | Once a quarter (once a month for high flexibility scenarios) | 1. Check the sheath wear of the drag chain and high flexibility cables, measure the sheath thickness, the wear shall not exceed 1/3 of the original thickness;2. Check the bending part of the cable, no sheath cracking, exposed insulation layer, conductor core breakage;3. Conduct bending test on the cable, no cracking, no insulation resistance drop;4. Check the cable fixing and guiding devices, no looseness, jamming, friction. | 1. If the sheath wear exceeds 1/3 of the original thickness, replace the cable immediately to avoid insulation failure caused by sheath damage;2. If sheath cracking, exposed insulation layer or conductor core breakage is found, cut off the power and stop the machine immediately, replace the cable, and continue to use is strictly prohibited;3. If the insulation resistance drops after the bending test, replace the cable immediately;4. If the fixing and guiding devices are loose or jammed, repair them immediately to avoid cable damage during operation. | |
| Current Carrying Capacity and Temperature Monitoring | Once a quarter | 1. When the cable is running under full load welding, use an infrared thermometer to test the surface temperature of the cable conductor and outer sheath, arrange test points evenly along the full length of the cable, focusing on the joints, turns, densely laid parts, and friction parts;2. The outer sheath temperature of the cable shall be ≤ the long-term allowable operating temperature of the insulation material, no local overheating point, no abnormal temperature rise;3. Test the influence of ambient temperature, laying method, friction heating on the current carrying capacity, and verify whether the actual operating current of the cable is within the allowable current carrying capacity range. | 1. If local overheating or abnormal temperature rise of the cable is found, check the cause immediately, test whether there is overload, local short circuit, insulation aging, poor contact, friction heating;2. If the operating current exceeds the allowable current carrying capacity, reduce the load immediately, check the cause of overload, and replace the cable with a larger cross section if necessary;3. If the overall temperature of the cable is overheated, stop the machine immediately, check the influence of ambient temperature, laying method, heat dissipation conditions, and optimize the laying and heat dissipation scheme. | |
| Annual Comprehensive Inspection and Long-term Operation and Maintenance | Comprehensive Electrical Performance Test | Once a year (non-operation period) | 1. Complete the full set of electrical performance tests of the cable according to the national standard requirements, including core indicators such as insulation resistance, withstand voltage, conductor resistance, capacitance, dielectric loss, and grounding resistance;2. All test indicators must meet the national standard and product technical requirements, no unqualified items;3. Compare the test data over the years, analyze the change trend of cable performance, predict the aging situation, and formulate operation and maintenance and replacement plans. | 1. If the test indicators are unqualified, check the cause immediately, and replace the cable if necessary;2. If the cable performance continues to decline and the aging trend is obvious, formulate a replacement plan in advance to avoid sudden failure during the operation period;3. If the transmission performance of the signal control line declines, check it immediately and replace the unqualified cable. |
| Full Life Cycle Ledger Update | Once a year / after each maintenance and replacement | 1. Establish a full life cycle operation and maintenance ledger for the cable, recording the cable model specification, material, laying date, laying position, test records, maintenance records, replacement records, and scrap records;2. Update the ledger in time after each test, maintenance and replacement to ensure the ledger information is complete and traceable;3. After the annual test is completed, fully update the ledger, analyze the cable operation status, and formulate the operation, maintenance, test and replacement plan for the next year, focusing on the cables in high flexibility, outdoor, and high current scenarios. | 1. If the ledger information is missing or incomplete, supplement it immediately to ensure the traceability of the operation and maintenance information of all cables;2. If the cable operation life is close to the product design service life, formulate a replacement plan in advance to avoid extended use beyond the service life;3. Cables that have been repaired many times and have continuous performance decline shall be included in the key monitoring, and scrapped and replaced in advance if necessary. | |
| Scrap and Replacement Management | Implemented according to actual test results | 1. The cable must be scrapped and replaced immediately if any of the following conditions occurs:① The insulation resistance and withstand voltage test are unqualified and cannot be repaired;② The outer sheath and insulation layer are seriously damaged, aged, cracked and cannot be repaired;③ The conductor core is broken or short circuited and cannot be repaired;④ The operation life exceeds the product design service life and the performance is seriously reduced;⑤ Accidents such as short circuit, overload, fire, mechanical rolling, freezing, high temperature burn have occurred, and the cable performance is damaged;⑥ The sheath wear exceeds 1/3 of the original thickness, or the bending life expires, with serious wear and cracking;2. Scrap cables must be marked, strictly prohibited from being reused, and disposed of in accordance with environmental protection regulations;3. The replacement cable must be a compliant product of the same specification, model and material, and can be put into use only after passing the test after installation. | 1. If the cable meets the scrap conditions, cut off the power and stop the machine immediately, continue to use is strictly prohibited, and arrange for professional personnel to replace it;2. The replacement cable must be laid, installed and tested in strict accordance with the specifications, and can be put into use only after passing the test, and the bending life test must be done for high flexibility scenarios;3. Scrap cables shall be disposed of in accordance with environmental protection regulations, and random discarding, secondary sales and non-standard reuse are strictly prohibited. | |
| Operation and Maintenance Personnel Training and Specification Update | Once a year | 1. Conduct training on cable professional knowledge, safe operation procedures, and emergency handling skills for operation and maintenance personnel and welding operators, focusing on the identification and emergency handling of cable wear, damage, and heating, and they can only take up their posts after passing the assessment;2. Update the latest national/industry standards and specifications in a timely manner, and synchronously update the operation and maintenance management system and operation standards, focusing on updating the operation and maintenance requirements for high current, high flexibility, and outdoor scenarios;3. Summarize the annual operation and maintenance experience, analyze the causes of high-frequency failures, optimize the operation and maintenance plan, and improve the operation and maintenance management level and the safety awareness of operators. | 1. Operators who fail to pass the training assessment are strictly prohibited from taking up their posts, especially for high current and outdoor welding operations;2. If the operation and maintenance system is not updated in a timely manner after the standards and specifications are updated, rectify it immediately;3. For high-frequency failures occurring in annual operation and maintenance, formulate a special rectification plan to avoid recurrence. |