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About UsJiaozuo Hanhe Cable Co., Ltd. is a wholly-owned subsidiary of Qingdao Hanlan Co., Ltd. Its predecessor was the Jiaozuo Cable Factory. Established in July 2005, it is a high-tech enterprise primarily engaged in the manufacturing of wires and cables.
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ProductWe can manufacture over ten thousand specifications and models of high-, medium-, and low-voltage wire and cable products, including 500 kV and lower voltage cross-linked power cables, overhead insulated cables up to 35 kV, plastic power cables up to 3.6/6 kV, plastic-insulated control cables, various flame-retardant and fire-resistant wires and cables, and overhead stranded conductors, spanning dozens of series.
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Prototype Development of Smooth Aluminum-Sheathed Cables: A Tough Journey Toward the High-Voltage Market—Cheng Yonggang, Planner in the High-Voltage Workshop
Release time:2025-12-12
In 2004, the Jiaozuo Municipal Government embarked on a difficult journey of exploration—crucial to the survival of Henan Jinlong Cable Co., Ltd. (formerly the Jiaozuo Cable Factory)—as the company teetered on the brink of closure.
Throughout my long journey in the cable industry, I personally took part in the pilot production of the 500kV, 2500mm² cross-linked polyethylene-insulated, smooth-aluminum-sheathed cable by Jiaozuo Hanhe in Jiaozuo. This experience is like a brilliant pearl, deeply embedded in the annals of my career, constantly inspiring me to keep moving forward.
At 2 p.m. on September 3, 2022, the critical production process—aluminum sheathing plus diameter reduction followed by outer jacket extrusion—for the ZC-YJLP03-Z290/500kV 1×2500mm² smooth aluminum-sheathed power cable was officially launched in the crosslinking workshop of the Jiaozuo company. My colleagues and I in the workshop stood ready, anxiously yet excitedly stationed beside the production equipment, closely monitoring the operational status of every single stage. At 7 p.m., when the entire cable jacket extrusion process was smoothly completed, the workshop instantly erupted into jubilation. Cheers and applause mingled together. We deeply understood that this achievement was the result of countless people’s hard work and dedication. Once again, Jiaozuo Hanhe has achieved a significant breakthrough in the high-voltage market sector.
As a member of the high-pressure workshop, I was fully involved in this pilot production effort and have deeply experienced its ups and downs—its sweetness, sourness, bitterness, and everything in between. Chairman Dong Jian personally led the team, guiding the entire Jiaozuo company to prepare enthusiastically. From fine-tuning the equipment to meticulously preparing tooling and materials, and right through to preliminary trial runs at critical points, every step was repeatedly scrutinized and refined, with the goal of ensuring absolute perfection.
However, the path to prototype development was far from smooth. The very first challenge was winding the semiconductive butyl rubber buffer tape. Since the Jiaozuo company had been using this type of buffer tape—whose one side was already coated with adhesive—frequent issues arose during the winding process, such as adhesion to the guide rollers and the formation of wrinkles. Despite numerous adjustments to the equipment, these problems remained unresolved. Just then, Li Cunyong, the operator of the winding machine, drew on his wealth of practical experience and keen powers of observation to come up with an innovative idea: wrapping an EVE rubber sheet around the area where the semiconductive butyl rubber buffer tape passed. This ingenious solution successfully eliminated the problem of the buffer tape sticking to the guide rollers, clearing the way for subsequent production stages. This experience profoundly made me realize that the wisdom and expertise of frontline workers hold immeasurable value in production practice—they are the key force in solving real-world problems.
The next challenge was debugging the argon arc welding of aluminum tubes and addressing the appearance issues that arose after diameter reduction. The aluminum strip used this time had a thickness of 2.0 mm, yet we needed to produce aluminum tubes with an outer diameter of 151 mm—exceeding the maximum production capacity of Jiaozuo Company’s argon arc welding equipment. Faced with this difficult problem, the team members did not flinch in the slightest. Through continuous improvements to various forming dies, flare dies, and welding die holders, and after countless rounds of debugging and experimentation, we finally managed to produce aluminum tubes that met the required specifications. However, after diameter reduction, the aluminum tubes once again exhibited a problem: the weld seam area was visibly concave inward. To address this issue, we carefully adjusted the roundness on both sides of the weld seam and meticulously fine-tuned the welding current. After repeated trials, we ultimately succeeded in resolving the problem of the concave appearance at the weld seam following diameter reduction.
The last remaining challenge to overcome was the bonding issue between the aluminum tube and the outer jacket. To achieve a reliable bond between the two, we successfully addressed this difficult problem by employing process treatments such as surface cleaning and heating of the aluminum tube. Throughout the entire pilot production phase, the manufacturing of smooth-aluminum-jacket cables proved far more challenging than that of conventional corrugated-aluminum-jacket cables. The manufacturing process for these cables requires one-step forming; during jacket production, the welding of the aluminum jacket, the reduction of the aluminum tube’s diameter, and the extrusion of the jacket must be carried out simultaneously, involving the coordinated operation of multiple pieces of equipment. Any malfunction in any single stage could lead to a complete shutdown of the entire production line, resulting in substantial losses. This high-precision, high-demand production model undoubtedly poses greater challenges to our production management, equipment operation, and process control.
However, as the saying goes, “Effort never betrays those who put their heart into it.” Through the team’s relentless efforts, we’ve finally succeeded in developing a smooth aluminum-sheathed cable. Behind this achievement lies the collaborative effort of all relevant personnel at the Jiaozuo company. The close and seamless cooperation between the headquarters and the Jiaozuo company has also been a key factor driving the project’s success. From the meticulous R&D and strategic planning carried out by the headquarters’ R&D department to the full-hearted cooperation and tenacious problem-solving on the production floor at the Jiaozuo company, every department and every position has played an indispensable role. Relying on our spirit of daring to take on challenges and proactively stepping up, we’ve seized this opportunity. Leveraging Hanhe Cable’s strengths in the high-voltage field, we’ve ridden the momentum to not only enhance our technical expertise and production capacity but also secure new competitive advantages and growth opportunities for the company in the market.
Looking back on this trial-production journey, every single day and night of intense effort remains vividly etched in my memory. We tackled one technical challenge after another, overcame numerous obstacles, and with our wisdom and hard work, wrote a brilliant chapter for Hanhe Cable in the high-voltage cable industry. This experience has not only greatly enhanced my professional skills and teamwork abilities, but has also deeply taught me that as long as all members share the same vision and pool their efforts together, no difficulty is insurmountable. On its journey in the high-voltage market, Hanhe Cable will continue to forge ahead bravely and create even more remarkable achievements.
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To promote the high-quality development of the enterprise and further enhance the core competitiveness of Jiaozuo Hanhe Cable Co., Ltd. in the wire and cable industry, we are now launching a public tender to assist the company in applying for the titles of “Excellent-Level Smart Factory” and “Digital Leading Enterprise.” The relevant tendering details are announced as follows:
Throughout my long journey in the cable industry, I personally took part in the pilot production of the 500kV, 2500mm² cross-linked polyethylene-insulated, smooth-aluminum-sheathed cable manufactured by Jiaozuo Hanhe in Jiaozuo. This experience is like a brilliant pearl, deeply embedded in the annals of my career, constantly inspiring me to keep moving forward.
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Address: Circular Economy Industrial Cluster Zone, Shanyang District, Jiaozuo City
Address: No. 228, Jianshe East Road, Shanyang District, Jiaozuo City