The manufacturing process of perforated cable trays involves several steps, ranging from material selection to the final product's finishing. Perforated cable trays are used to support and organize electrical cables and wires in industrial, commercial, and residential settings. The perforations in the trays allow for better ventilation, reduce weight, and facilitate cable management. Here’s a breakdown of the typical manufacturing process:
1. Material Selection
The most common materials used for perforated cable trays are:
1. Mild steel (often galvanized for corrosion resistance)
2. Stainless steel (for corrosion resistance in harsh environments)
3. Aluminium (lightweight and resistant to corrosion)
4. Fiberglass or plastic (for specialized applications, often in corrosive environments)
5. The material is chosen based on factors such as load-bearing requirements, environmental conditions, and cost.
2. Sheet Cutting
The process starts by cutting the selected raw material (metal sheet) into the required size. The metal sheets come in standard sizes, and they are cut to specific lengths depending on the required dimensions of the tray.
Cutting Methods: Shearing, laser cutting, or water jet cutting can be used to get the desired size. Laser cutting is often preferred for precision, especially for making holes.
3. Perforation
The key feature of perforated trays is the series of holes punched or drilled along the length of the tray. This step involves creating holes in the sheet metal to facilitate ventilation and reduce the weight of the tray.
Punching Machine: A CNC punching machine is commonly used for perforation. The machine automatically positions the sheet and uses a punch tool to create uniform holes.
Hole Size & Spacing: The diameter and pattern of holes can vary depending on the design requirements, typically ranging from small round holes to large elongated slots.
Customization: The spacing and size of the holes are adjusted to ensure maximum strength while providing sufficient ventilation and cable capacity.
Ladder type trays: Similar to perforated trays but with crossbars forming a "ladder" structure.
Channels or Troughs: More enclosed with sides and a bottom, providing additional support for cables.
The edges of the trays are often bent or folded to create smooth, safe edges that prevent damage to cables during installation.
4. Bending and Shaping
After perforation, the metal sheets are bent into the desired shape using a press brake machine or a roll forming machine. The trays can have different shapes, such as:
1. Straight trays: A simple, flat tray.
5. Welding (if applicable)
For certain designs (such as when the tray has additional features like side rails or supports), welding may be required. The edges or joints of the trays are welded together to form the final shape.
