Visit Longzhiyi Factory, Witness Every Production Step
From copper rod wire drawing to finished product packaging, from material preparation to terminal crimping, assembly and full inspection — the entire workflow is fully transparent. Below are real production operation videos for two major product lines: Cable Division and Harness Division, so you can see the quality with your own eyes.
Cable Division · Production Process
Complete manufacturing chain for copper cables, power cords and special cables from raw materials to finished goods
Raw Material Preparation · Incoming Inspection
Copper Rod Incoming Inspection
T1 copper content ≥99.95%, resistivity complies with GB/T 3953, spectral test for impurities and resistivity
Rubber & Plastic Material Test
PVC/TPU/XLPE pellets tested for tensile strength, insulation, melt index and flame retardancy
Formula & Mixing
Plasticizers, stabilizers and flame retardants formulated to GB/T 8815 and high-speed homogenized
Material Traceability Record
Batch number, origin and inspection data logged for every raw material batch for full-chain traceability
Conductor Processing · Wire Drawing & Annealing
Continuous Wire Drawing
Multi-die continuous drawing machine reduces diameter progressively, reduction rate 15%-20%, diameter tolerance ±0.02mm
Continuous Annealing
Nitrogen-protected annealing furnace at 280~350℃ eliminates cold drawing stress, improves toughness and lowers DC resistance
Single Wire Surface QC
Real-time monitoring of diameter and surface finish to prevent wire breakage and oxidation blackening
Ultra-Fine Copper Wire Fabrication
0.05~0.2mm ultra-fine copper wires for flexible cables to guarantee flexibility and bending life
Conductor Stranding
Bunch Stranding / Concentric Stranding
Frame strander performs directional regular stranding; adjacent layers run opposite direction with pitch-diameter ratio of 12~14
Compact Stranding
Round compacted conductors for industrial cables, reducing cable diameter with dense filling and low void ratio
Stranding Filler
Aramid yarn added to boost tensile strength and repeated bending resistance
Stranding Sampling Inspection
Full inspection on DC resistance, outer diameter and appearance to prevent loose strands and broken cores
Insulation Extrusion & Crosslinking
Single-Layer Insulation Extrusion
Single extrusion for PVC/B-grade cables, zone temperature control on extruder, insulation thickness tolerance ±0.1mm
Colour Stripe & Ring Marking
Marking process applied to identify cores for quick distinction of multi-core cables
Segmented Cooling & Setting
Three-stage cooling tank (60℃→40℃→ambient), cooling rate ≤15℃/min to avoid stress concentration
On-Line Spark Voltage Test
Full-line spark test; breakdown segments auto-trimmed to detect pinholes and missing gum defects
Cabling · Inner Sheath · Armoring
Cable Forming
Multiple insulated cores stranded at specified pitch; non-woven fabric / water blocking tape wrapped to fix cable core
Braided & Aluminum Foil Shielding
Aluminum foil + braided composite shielding to improve anti-EMI performance
Paper / Water-Blocking Tape Wrapping
Cable core wrapped by paper or water-blocking tape for isolation, cushioning and water resistance
Steel Tape Armoring
Helically wrapped steel tape enhances cable compression resistance and mechanical damage protection
Outer Sheath Extrusion
Sheath Extrusion
90mm extruder cladding; sheath thickness complies with GB/T 5023, minimum thin spot ≥ nominal ×0.85
Sheath Cooling & Setting
Segmented water tank cooling after sheath extrusion to control cooling rate and prevent surface shrinkage & deformation
Surface Ink Marking
Online inkjet printer prints model, trademark and specification marks
Coiling & Packaging
Coiling machine reels fixed-length cable, packed by specification for safe transportation
Wire Harness Division · Production Process
From material preparation & wire cutting, terminal crimping, assembly & molding to full inspection & packaging — restore complete harness manufacturing workflow
Material Preparation · Wire Cutting
Automatic Wire Cutting
CNC wire cutter cuts in batches per work order, length tolerance controlled within ±1mm
Manual Precision Cutting
Manual precision cutting for small batches & special-shaped wires, flexible for samples and custom orders
Sample Comparison Length Setting
Cut to length against reference sample to ensure neat and uniform wire bundle ends
Marker Tube Printing
Wire marking machine prints marker tubes for harness port traceability
Stripping · Processing
Outer Jacket Stripping
Precision stripper removes outer jacket with fixed length & depth without damaging inner cores
Core Twisting
Wire core twisting prevents loose strands and improves signal & anti-interference performance
Heat Shrink Tube Application
Heat gun shrinks tubing tightly over joints for insulation and strain relief
Wire End Tinning
Wire end tinning secures conductors and enhances soldering reliability
Termination · Soldering
Terminal Crimping
Terminal press forming; crimp height and pull force comply with IPC/WHMA-A-620 standard
Die Changeover
Die replacement for different terminal sizes; consistent flare and indentation
Auto Cut & Crimp
Automatic cut-strip-crimp machine completes wire feeding, stripping and terminal crimping in one continuous cycle
Harness Soldering
Constant-temperature iron with auto solder feeding; full bright solder joints with no cold solder or bridging
Assembly · Molding
Housing & Pin Insertion
Terminals inserted into connector housing by wire sequence, locked in place with anti-mistake design
Connector Assembly
Connector assembly with standardized structural fitting and locking
Injection Molding
Low-pressure injection encapsulates joints for integrated waterproof and pullout resistance
Dispensing / Hot Melt Encapsulation
Joint reinforcement by glue dispensing; hot melt fills joints for strain buffer and moisture barrier
Inspection · Packaging
Continuity Test
Tester checks wire sequence and continuity one by one to eliminate miswiring, open and short circuits
Hipot & Insulation Test
High & low voltage comprehensive electrical test covering continuity, withstand voltage and leakage indicators
Full Visual Inspection
100% visual check of appearance and assembly to reject defective products
Labelling & Packaging
Standard labeling for model and batch, one-item-one-code traceability; protective packaging for safe shipment
Full Process Operation Videos · Production Videos
Click any video card to play. When deployed, replace video URL in each card with your real video link
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