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Non-conformity of the cable .086 due to Insertion Loss instability after…
Non-conformity of the cable .086 due to Insertion Loss instability after shaking
Braid/Jacketing support
Low Strenght/Contact at Braid/Jacket interface
Jacket dimension change with time
wall thickness
Jacket wall thickness
too low
variation
Jacket compound penetration or flow into braid
Jacket extrusion temparture too low
Tooling too large
core contraction causing a gap between layers
Pollution FW
Pollution on FW during the process
contamination in MWS room
exposive to atmosphere during testing steps
dust in MWS room
dust or pllution inside MWS machine
poor silver saver paper installation
Pollution on FW contact surfaces
Pollution FW from supplier
ferrous contamination and oxydation
Lubrification from milling on the flat wire
metallic contamination
sulfer contamination silver-sulfide
[Batch 7] Pollution from Braid Process
abrasion on pulley not rotating
lubrification from OMA
carrier pulleys
excess lubrification
Capstan metal surface to cable contact
Poor cold welding
[Batch 7] Wrong FW mechanical properties
Hard FW (Low % Elongation)
will not cold weld
Low Yield strenght
Force to cold weld too high, will yield FW
Low force normal to overlap
Poor surface contact between FW layers
Wrong lay lenght
Variation during MWS operation
S shape of the ribbon impacted
FW tension too high
[Batch 7] Twisted or damaged FW during application
Wrong sized pulley
Twisted FW at setup
Profile of silver plating
Tarnish surface on FW
wrong handling or storage
poor packaging from supplier
exposed to air for extanded time
Sulfur air pollution causes silver-sulphite
prevents cold welding
ambiant air contamination (oil, lubricant, carbon, etc)
Rough surface on FW
[Batch 7] Damaged during FW wrapping (or other operations)
Damaged FW contact surfaces
[Batch 7] Rough surface of FW
Ordered w/ rough FW surface
worn mills/rollers at vendor
Small scale Ra variation between batches
Cold weld damaged after FW application
Lubrication contamination of Braid
Migrate into FW
Flexing destroys cold weld
[Batch 7] Torque/Twist of cable
open/unwind FW
(P3) expansion + contraction from temperature changes
Jacket extrusion temp shock
High extrusion temperature
Extruders thermo couples not set correctly
Rate of cooling too low
Contamination or pollution between FW layers
[Batch 7] Oil or lubrivcant contamination
Carbon contimination
Metallic contamination
Not enough silver plating at the middle of the FW
Plating removed at MWS process
From vendor
Lack of compression
[Batch 7] OD variation on Dielectric
[Batch 7] OD variation in process
[Batch 7] FW tension too low (TOFW)
FW tension not well defined (correct value is not known)
FW tension variation in process
F2 (Flat wire tension) not set correctly (empty tension offset)
Inconsistent repetability of calibration system
OD variation during MWS FW application
Lay lenght or pitch variation for FW
TOFW variation in process
FW thickness variation
FW relaxation
[Batch 7] FW is yielded
TOFW > Yield Strenght
TOFW variation during MWS
FW variation from supplier
Loose Braid
Incoming material Inconsistent (Inconsistent MWS diameter)
Dielectric OD Inconsistent
TOFW Variation at MWS
[Batch 7] Vibration during process
OMA Braiding Vibration
Rotational bobin speed too high
Guide position (alignement) on OMA inlet
Long cable lenghts shaking
Tension too low
unsupported lenght lenght too high
Machine shaking
Balance - Bearings wear
FW MWS Wrapping Vibration
F3-F1 Line tension
Machine Shaking
Balance Bearings wear
TOFW Variation during FW wrapping
F2 VS no F2 setup (Does it cause vibrations?)
[Batch 7] Twisting or Torque of Primary during MWS FW Wrap
Unwrap or work against FW wrap
Lost conductivity between FW layers
[Batch 7] Twisting caused by MWS FW wrapping
Stretches FW more
?? Yield FW
Very tight, MWS (like tube)
Rigid and inflexible FW layer
Flexure cause gaps, lowers conductivity between FW layers
Dielectric/CC motion on the finish cable
Lack of adhesion after primary core
Shrink back of dielectric after time
Gap between Dielectric + CC
Low elasticity from foam dielectric (compresses but does not expend back)
Foaming properties of dielectric
High void content
Void/Bubble Distribution on the radius
Compound properties
Vois/Bubble size
Too much compression from FW destroys foam structure
High FW tension (TOFW)
extention during jacketing