A HDMI cable production process

Abstract

The invention relates to a HDMI cable production process in the technical field of HDMI cable production. The invention adopts a plurality of processes to cooperate with each other to complete the manufacture, detection, decoration, packaging and storage of the HDMI cable, reduces the expenditure of labor cost through the automated process, increases the product quality rate, and improves the need for outsourcing to factories in traditional processes. The process flow improves the defects and outsourcing steps of the existing process, reduces the occurrence of management errors or increases in process time, improves work efficiency, and reduces the risk of process breakage. Different processes are adopted to respectively complete the manufacturing process flows of HDMI AM TO AM high-definition cables of 0.7 to 5 meters, HDMI AM TO AM high-definition cables of 8 to 15 meters, and HDMI AM TO AM gold-plated black round cables of 25 to 30 meters. While ensuring that different line types and lengths are met, the production risk is reduced through the automated process.

Description

Technical Field

[0001] The present invention relates to the technical field of HDMI cable production, and in particular to a HDMI cable production process. Background Art

[0002] HDMI stands for High-Definition Multimedia Interface. This cable is a digital interface standard for transmitting uncompressed audio and video signals. It is widely used to connect devices such as TVs, computer monitors, projectors, and game consoles. The production process of HDMI cables is a complex and delicate process involving multiple steps and technologies to ensure the quality and performance of the final product.

[0003] The existing Chinese patent with reference announcement number CN116780247A discloses an HDMI interface structure and its production process, including an interface component and a wiring mechanism, wherein the interface component includes a metal shell, a support block and a plug board; the wiring mechanism includes a plurality of metal tubes, a plurality of metal sheets, a groove, two pressure strips, a plurality of connecting sheets, a plurality of clamping sheets and a plurality of piercing heads; the support block is arranged on one side of the metal shell, and the plug board is arranged inside the metal shell; the present invention inserts the moving cable into the inside of the metal tube, and then squeezes the pressure strip to drive the clamping sheet and the piercing head to be inserted into the groove, and the clamping sheet squeezes the inner side of the groove to deform the clamping sheet to clamp and fix the cable, and then the moving piercing head pierces the middle part of the cable to quickly connect the metal tube and the cable, so that the wiring can be completed without welding, and the wiring work of all cables can be completed at one time, thereby improving the overall production efficiency of the HDMI interface.

[0004] Although this patent contains relevant content about HDMI cables and their production process, it does not fully disclose the production process of HDMI cables. When coordinating the processes of current HDMI cables, some processes still need to be outsourced, which increases the possibility of management errors or increases the process time. For this reason, the inventors have proposed a HDMI cable production process to solve the above-mentioned technical problems. Summary of the invention

[0005] In order to overcome the above-mentioned shortcomings, the invention aims to provide a technical solution that can solve the above-mentioned problems.

[0006] A HDMI cable production process, the process comprising the following steps:

[0007] S1: Wire cutting & winding. During wire cutting, the wire is cut to the required length by an automatic wire cutter. After cutting, the wire stripper is used to remove the insulation layer at both ends of the wire to expose the internal metal conductor. Then, a wire winding machine or a wire twisting machine is used to twist the multiple strands of wire together in a specific way to ensure the quality of signal transmission. Finally, the terminal crimping machine is used to crimp the terminal of the HDMI connector and the internal wire together. The rolled HDMI wire is loaded into the automatic wire cutter, and the wire cutter parameters, including cutting length and quantity, are set. Then the machine is started to automatically complete the cutting and check whether the cut wire length meets the requirements.

[0008] When winding or twisting the wires, you need to use a winding machine to twist them into a composite cable. Install each strand of wire correctly on the winding machine, set the winding direction and tightness according to the needs, start the winding process, ensure that the wires are closely arranged to reduce electromagnetic interference, and check the cable quality after winding to ensure that there is no uneven winding or loose areas.

[0009] S2: Strip the outer sheath. Use the 315 horizontal stripping machine to accurately strip the outer sheath of the cable according to the set parameters. Arrange the HDMI cables to be processed neatly and prepare space for the processed cable segments.

[0010] According to the specific specifications, diameter and material of the HDMI cable, adjust the relevant parameters of the wire stripping machine, cutting depth and length, correctly put the HDMI cable into the fixing device of the wire stripping machine, ensure that the wire is stable and immovable, press the start button to make the wire stripping machine work according to the preset parameters, and after stripping the outer sheath, carefully check whether the wire is damaged, and whether the shielding layer and signal line protecting the inside are damaged. Finally, remove the stripped waste and properly place the wire that has been stripped of the outer sheath to prepare for the next step;

[0011] S3: Cut braiding, ensure that the HDMI cables to be processed are arranged neatly, and prepare space for the processed cable segments. According to the specific specifications, diameter, and material of the HDMI cables, adjust the relevant cutting depth of the wire stripping machine to ensure that only the braided layer is cut without damaging the internal wires. Determine the length of the outer sheath to be stripped and the braided layer to be cut. Put the HDMI cable correctly into the fixture of the wire stripping machine / cutter braiding machine, ensure that the wire is stable and motionless, press the start button, and let the machine work according to the preset parameters. After the cutting and braiding process is completed, carefully check whether the wire is damaged, and avoid protecting the internal shielding layer and signal line from damage. After the braiding is even, turn it over and cut it cleanly, and keep the ground wire;

[0012] S4: Cut the aluminum foil manually using aluminum foil scissors or utility knife. Since aluminum foil easily generates static electricity and absorbs dust, an electrostatic eliminator is required during the processing of the aluminum foil. The operator tears off one end of the aluminum foil to separate it from the HDMI cable. Use special aluminum foil scissors or utility knife to trim the aluminum foil layer along the required length, keeping the edges neat to avoid cutting the internal wires. Then use a dust-free cloth or air gun to clean off any remaining small pieces of aluminum foil to prevent it from entering between the internal wires. Finally, check whether all the aluminum foil is neatly cut and there is no residue adhering to the internal wires. Arrange the wires for the next step.

[0013] S5: Laser cutting & removing aluminum foil Mylar. Use a laser cutting machine to remove aluminum foil Mylar. The laser cutting machine can achieve fine processing of different materials by controlling the energy, speed and focal position of the laser beam. A vacuum adsorption platform is used to fix the wire to ensure that the wire will not move during the laser cutting process, thereby ensuring cutting accuracy. Adjust the relevant parameters of the laser cutting machine, including laser power, scanning speed, and frequency, to ensure that only the aluminum foil Mylar layer is cut without damaging the internal wires. Then start the laser cutting machine and work according to the preset parameters. The laser will cut the aluminum foil Mylar layer along the set path without damaging the shielding layer and signal line below. After the process is completed, carefully check the cut wire to ensure that the internal structure is not damaged.

[0014] S6: Put 2 sleeves on both ends, use a hot air gun or heat shrink oven to shrink the sleeves to make them fit tightly against the cable and connector, remove impurities on the cable surface, and properly place the processed wires to prepare for the next step. Then select the appropriate size of sleeve according to the cable diameter and pre-cut it into appropriate lengths as needed. First slide the sleeve over one end of the HDMI cable until it is in a position that will not hinder subsequent operations. When the components are assembled, slide the sleeve to the predetermined position, covering the root of the connector and the end of the cable. Check whether the sleeve completely covers the expected area and the appearance is neat and not reversed; then organize the wires for the next step;

[0015] S7: Two aluminum caps are inserted on both sides in the middle. The purpose of inserting aluminum caps on both sides in the middle is to enhance the electromagnetic shielding performance and mechanical protection of the cable. Select the aluminum caps of appropriate sizes by manually installing the aluminum caps, and check their quality in advance as needed. Use appropriate cleaning tools to clean the surface of the cable to ensure that there is no dust or other impurities that affect the installation of the aluminum caps. Put the aluminum caps into the HDMI cable at the specified position to ensure that they are in the correct position. Use crimping pliers to crimp the aluminum caps to ensure that they fit the cable firmly and keep the crimping uniform to avoid damaging the internal structure of the cable. Then carefully check whether the aluminum caps are correctly installed and ensure that they are not skewed or loose.

[0016] S8: A yellow protective net is placed in the middle. The protective net is a braided net or winding tube. Its function is to enhance the mechanical strength of the cable and provide additional electromagnetic shielding. An automatic braiding machine or winding machine is used to adjust the braiding density and winding spacing. The yellow protective net is braided or wound at the specified position to ensure that it covers the entire area to be protected. The braiding or winding process is completed automatically to ensure that the yellow protective net fits firmly. After the process is completed, carefully check whether the yellow protective net covers the cable evenly and tightly to ensure that there is no looseness or unevenness. Trim the excess part to achieve the ideal length and appearance. The wires that have completed the installation of the yellow protective net are properly placed to prepare for the next process.

[0017] S9: Cable arrangement*4. Cable arrangement is to arrange and fix multiple strands of internal wires in a specific order to ensure the quality and stability of signal transmission. An automatic cable arrangement machine is used to quickly and accurately arrange multiple strands of wires in a predetermined order and fix them. A microscope or magnifying glass is used to check the cable arrangement quality. A vernier caliper or micrometer is used to ensure the accuracy of the wire arrangement. A welding or crimping tool is used to fix the arranged wires to the connector terminals. The working area and cable surface are cleaned to ensure that there is no dust or other impurities that affect the cable arrangement quality. Then the wires are sorted and the wires that have been arranged and fixed are properly placed to prepare for the next step.

[0018] S10: Double stripping*4, through the double stripping process, the same wire is stripped twice at different positions. This process is used to separate the shielding layer and the signal line, or to prepare for the installation of the connector. The double stripping operation is completed by an automatic double stripping machine. During the double stripping sample inspection, a microscope or magnifying glass is used to check the quality after double stripping, and then the start button is pressed to let the machine perform the first stripping according to the preset parameters, and then move to the specified position for the second stripping;

[0019] The first stripping is to cut the outer sheath at the designated position, carefully peel off the outer sheath to expose the internal structure, and the second stripping is to move to another designated position, repeat the above steps for the second stripping operation, and properly place the processed wires to prepare for the next step;

[0020] S11: Tinning*4. The tinning process is to improve the conductivity, prevent oxidation and facilitate subsequent welding. The ends of the internal multi-strand wires are tinned. A manual soldering iron and tin wire are used in a tin furnace. The flux is applied by a flux coating device before tinning to ensure that the tin can be evenly attached. After cleaning the flux residue, manual tinning is performed by a tin furnace to ensure the cleanliness after tinning. After tinning, the wire is moved to the cooling area and waited for natural cooling or a cooling device is used to accelerate the cooling process. After the process is completed, the excess tin slag is removed and the treated wire is properly placed to prepare for the next process.

[0021] S12: Installing the plug*4. Installing the plug means installing the connector. This process directly affects the function and quality of the finished cable. The terminal of the HDMI connector is crimped together with the internal wire through an automatic terminal crimping machine. The crimping makes the direction of the wire clamp consistent. The HDMI connector assembly equipment is used to fix the connector shell, insert the terminal, connect the shielding layer or the part that needs to be welded through an ultrasonic welding machine, and then use a continuity tester or a tension tester to ensure the electrical performance and mechanical strength of the connector after installation. After the strength test, the shell of the HDMI connector is put in and fixed with a screwdriver or other tools to ensure that it fits the cable tightly to ensure its normal operation.

[0022] S13: High-frequency welding*4. High-frequency welding is ultrasonic welding or high-frequency induction welding. The high-frequency current of the high-frequency welding machine generates heat to achieve fast and precise welding. The HDMI cables to be processed are neatly arranged, and space for the processed cable segments is prepared. After welding, the cables are moved to the cooling area and wait for them to cool naturally or use a cooling device to accelerate the cooling process. The welding points are carefully checked to ensure that the welding is firm and there is no false welding or over-welding to ensure its normal operation.

[0023] S14: Solder joint inspection*4. Solder joint inspection is a key step to ensure welding quality, electrical performance and mechanical strength. An ultrasonic detector is used to detect whether there are cold joints or bubbles inside the solder joints. The inspection results are recorded manually to mark unqualified solder joints. For solder joints marked as unqualified, they are carefully inspected and necessary repairs are made to ensure that they meet the quality standards. Then a tensile tester is used to apply a certain tensile force to the solder joints to ensure that they can withstand the specified force without falling off. The wires that have been inspected and repaired are properly placed to prepare for the next step.

[0024] S15: Test semi-finished products*2. This process uses a wire comprehensive tester to test the electrical conditions according to the drawings. The tests include continuity test, insulation resistance test, and withstand voltage test. The results are manually tested and unqualified items are marked. For cables marked as unqualified, they are carefully inspected and necessary repairs are made to ensure that they meet the quality standards. The cables that have been tested and repaired are properly placed to prepare for the next process.

[0025] S16: Use a 2.0T vertical molding machine to mold the inner molds at both ends of the cable. There must be no glue missing during molding.

[0026] S17: Form the middle aluminum mold using a 2.0T vertical molding machine. The inner molds at both ends of the cable must not be lacking in glue.

[0027] S18: Second test: 2 semi-finished product inner molds, use wire comprehensive testing machine to test according to the electrical conditions of the drawing, record the test results manually, mark the unqualified solder joints, carefully check and make necessary repairs for the solder joints marked as unqualified to ensure that they meet the quality standards, and properly place the wires that have been tested and repaired to prepare for the next process;

[0028] S19: Use a 2.0T vertical molding machine to form the middle mold at both ends of the cable. There must be no glue missing during the inner mold molding at both ends of the cable.

[0029] S20: Use a 2.0T vertical molding machine to mold the outer molds at both ends of the cable. There must be no glue missing when molding the inner molds at both ends of the cable.

[0030] S21: The aluminum mold in the middle is formed using a 2.0T vertical forming machine. The inner molds at both ends of the cable must be formed without any glue missing.

[0031] S22: Assemble the amplifier, weld the amplifier module to the internal wires of the HDMI cable, fix the amplifier housing and insert the circuit board, align the amplifier module with the HDMI cable at the specified position and fix it on the cable, use an automatic welding machine or manual welding tools to accurately weld the pins of the amplifier module to the internal wires of the HDMI cable, ensure that each wire corresponds to the correct pin, then put the housing of the amplifier module in and fix it with a screwdriver or other tools, ensure that it fits the cable tightly and does not affect the internal connection, use a signal generator and an oscilloscope to perform a functional test on the amplifier to ensure that it can correctly amplify and transmit HDMI signals, and pay attention to the direction of the input and output ends of the amplifier;

[0032] S23: Test of semi-finished products. Use wire comprehensive testing machine to test according to the electrical conditions of the drawing. This process adds an amplifier test. Pay attention to the direction of the amplifier's inlet and outlet during the test.

[0033] S24: Assemble the copper tube. This step is used to enhance the mechanical strength of the cable, provide additional electromagnetic shielding, and serve as a supporting structure inside the heat shrink tubing. An automatic copper tube insertion machine is used to insert the copper tube into the specified position of the HDMI cable. When checking the quality, it is necessary to check whether the copper tube is correctly inserted into place to ensure that it fits firmly into the internal structure of the cable and does not affect other components.

[0034] S25: Install the hexagonal screws. Prepare the hexagonal screws, washers and nuts, and check their status in advance as needed. Find the screw holes at the designated locations and make sure they match the hexagonal screws. Use a manual screwdriver or torque wrench to screw the hexagonal screws into the screw holes and make sure they can go in smoothly.

[0035] S26: Put on the yellow protective net, the outer layer is a woven net or a winding tube, start weaving or winding the yellow protective net at the designated position to ensure that it covers the entire area to be protected, and then trim the excess part to achieve the ideal length and appearance, and properly place the wires that have been installed with the yellow protective net to prepare for the next step;

[0036] S27: Finished product testing, using a wire comprehensive testing machine to test the electrical conditions according to the drawings, manually record the test results, mark the unqualified records, check the corresponding component structures of the records marked as unqualified and make necessary repairs to ensure that they meet the quality standards, and properly place the wires that have been tested and repaired to prepare for the next process;

[0037] S28: Audio and video test. Testing with a 4K TV and a signal source can simulate actual usage scenarios and verify whether the HDMI cable can stably transmit high-definition audio and video signals. Prepare a 4K ultra-high-definition TV that supports HDMI 2.0 or above in advance, and prepare a 4K signal source device in advance. The 4K signal source device includes a Blu-ray player, a 4K streaming box, a game console, or a dedicated HDMI signal generator. During the test, ensure that the light in the test environment is moderate to avoid excessive or weak light affecting visual judgment and external noise interfering with the audio test. Connect the signal source to the HDMI cable, connect the HDMI output port of the 4K signal source device to one end of the HDMI cable to be tested, and insert the other end of the HDMI cable to be tested into the HDMI input port of the 4K TV. Turn on the 4K TV and select the correct HDMI input channel. Turn on the signal source device and ensure that it is set to 4K resolution output.

[0038] Select a high-quality 4K video content on the signal source device and play it. Pay attention to whether there is any abnormality in the picture on the TV screen, whether the image clarity and color reproduction are normal, whether there is any picture freeze, frame drop or flicker, whether there is obvious image noise or distortion, and use the TV menu to confirm whether the current displayed resolution and refresh rate reach 4K and 60Hz;

[0039] Pay attention to whether there is any abnormality in the audio, whether the sound is clear, whether the stereo effect is good, whether there is audio delay or synchronization problem, whether there is popping sound, noise or abnormal sound, record the results of each test, including the type of signal source used, the content played, and the phenomenon observed. After the test is correct, properly place the HDMI cable that has passed the test and prepare for the next process;

[0040] S29: Blowing the sleeve. In this step, a hair dryer is used to put the sleeve on the surface of the cable. The sleeve is shrunk by blowing hot air with temperature through the hair dryer. After the process is completed, it is tested to ensure that the wire is not damaged by the blow. The qualified HDMI cable is properly placed to prepare for the next process.

[0041] S30: labeling. This step is done manually and the label cannot be pasted upside down.

[0042] S31: Appearance inspection, use a utility knife to trim the sharp edges or burrs, and pay attention to the printing direction. There should be no glue missing;

[0043] S32: Wire winding & Velcro binding. This step involves manual wire winding according to the drawing requirements. The wire winding consists of three turns in one bundle. The wire winding is assisted by a winding reel or a winding board. After the wire winding is completed, the wire is moved to the binding table and assisted by a Velcro binding fixture. The Velcro tape is then wrapped around the cable at the designated position to ensure that it fits tightly but not too tight to avoid damaging the cable.

[0044] S33: Finished product testing, using a wire comprehensive testing machine to test the electrical conditions according to the drawings, manually record the test results, mark the unqualified records, check the corresponding component structures of the records marked as unqualified and make necessary repairs to ensure that they meet the quality standards, and properly place the wires that have been tested and repaired to prepare for the next process;

[0045] S34: Check and clean the hardware. Sampling is used for testing. The wires must not be dirty or crushed by the hardware. The corresponding component structures marked as unqualified are checked and reported.

[0046] S35: Installing a protective cover, which is a heat shrink protective cover. In this step, a hair dryer is used to put the protective cover on the surface of the cable, and hot air is blown out by the hair dryer to shrink the protective cover. After the process is completed, an inspection is performed to ensure that the wire is not damaged by the blow, and the qualified HDMI cable is properly placed to prepare for the next process;

[0047] S36: Full inspection of appearance & cleaning of wire / bagging,

[0048] The inspection is carried out by sampling the appearance of the whole inspection. Cleaning is carried out with a dust-free cloth or a special cleaning cloth, an air gun or a compressed air tank. The cleaning agent is isopropyl alcohol. Wipe the cable material under the premise of ensuring its safety. After wiping, use an electrostatic eliminator to prevent static electricity from absorbing dust. After the process is completed, bagging is carried out. Antistatic bags or antistatic foam are used for bagging.

[0049] S37: Attach 69 label / attach SN anti-counterfeit label, use label printer to print 69 barcode label and SN anti-counterfeit label, and attach the label according to the drawing requirements;

[0050] S38: Fold color boxes / install certificates / install color boxes, use automatic folding machines to fold color boxes, prepare certificates and use label printers to generate certificates, ensuring that the information on each certificate is unique and meets the standards.

[0051] Make sure that the HDMI cable to be packed into the color box has completed all necessary pre-processing, including labeling and cleaning. Prepare all accessories, instructions, and warranty cards that need to be packed together and put them into the cable and accessories. Then carefully put the HDMI cable into the color box to ensure that it is not squeezed or twisted. Put all accessories that need to be packed together in order according to the pre-designed positions. Make sure that all items in the color box are complete and neatly arranged. Finally, use a heat sealer or tape sealer to seal the color box to ensure that it is firmly sealed to prevent moisture or contamination during transportation;

[0052] S39: Scan the barcode / check the barcode / external inspection. Use a barcode scanner to scan each label to ensure that its content is correct and matches the record in the database. Carefully check whether the label is correctly pasted in place, ensure that it is flat, free of bubbles, and skew, and that there are no missed scans. External inspection is carried out by sampling.

[0053] S40: Paste the outer box label, use the label printer to print the outer box label, and paste the label according to the drawing requirements;

[0054] S41: Packing / sealing / weighing, use a hot melt glue gun or tape sealer to seal the cartons, apply glue or tape evenly along the opening of the carton to ensure a firm seal, do not over or under pack, carefully check the sealed cartons to ensure they are structurally sound, neat in appearance, without damage or skew, confirm that the sealing materials are completely dry or firmly affixed to prevent the cartons from loosening or getting damp during transportation; place the sealed cartons on an electronic scale and record their weight, store the weighed and labeled cartons properly, and prepare for warehousing or shipment.

[0055] Furthermore, in S2, the size is ensured to be within the requirement of 28+ / -2mm.

[0056] Furthermore, in S10, the core stripping size is 2+ / -0.5 mm, and the core wire must not be damaged.

[0057] Compared with the prior art, the present invention has the following beneficial effects: the present invention adopts multiple processes to cooperate with each other to complete the manufacturing, testing, decoration, packaging and warehousing of HDMI cables, reduces the expenditure of labor costs through automated processes, increases the quality rate of products, and improves the need for outsourcing factories in traditional processes;

[0058] This process improves the defects and outsourcing steps of the existing process, reduces the occurrence of management errors or increases in process time, improves work efficiency, and reduces the risk of process interruption;

[0059] Different processes are used to complete the manufacturing process of HDMI AM TO AM high-definition cable 0.7-5 meters, HDMI AM TO AM high-definition cable 8-15 meters and HDMI AM TO AM gold-plated black round cable 25-30 meters. While ensuring that different line types and lengths can be met, the production risk is reduced through automated processes. DETAILED DESCRIPTION

[0061] The present invention is further described in detail below in conjunction with specific implementation modes.

[0062] This embodiment 1:

[0063] A specific HDMI line production process is implemented, and the process includes the following steps:

[0064] S1: Wire cutting & winding. During wire cutting, the wire is cut to the required length by an automatic wire cutter. After cutting, the wire stripper is used to remove the insulation layer at both ends of the wire to expose the internal metal conductor. Then, a wire winding machine or a wire twisting machine is used to twist the multiple strands of wire together in a specific way to ensure the quality of signal transmission. Finally, the terminal crimping machine is used to crimp the terminal of the HDMI connector and the internal wire together. The rolled HDMI wire is loaded into the automatic wire cutter, and the wire cutter parameters, including cutting length and quantity, are set. Then the machine is started to automatically complete the cutting and check whether the cut wire length meets the requirements.

[0065] When winding or twisting the wires, you need to use a winding machine to twist them into a composite cable. Install each strand of wire correctly on the winding machine, set the winding direction and tightness according to the needs, start the winding process, ensure that the wires are closely arranged to reduce electromagnetic interference, and check the cable quality after winding to ensure that there is no uneven winding or loose areas.

[0066] S2: Strip the outer sheath. Use the 315 horizontal stripping machine to accurately strip the outer sheath of the cable according to the set parameters. Arrange the HDMI cables to be processed neatly and prepare space for the processed cable segments.

[0067] According to the specific specifications, diameter and material of the HDMI cable, adjust the relevant parameters of the wire stripping machine, cutting depth and length, correctly put the HDMI cable into the fixing device of the wire stripping machine, ensure that the wire is stable and immovable, press the start button to make the wire stripping machine work according to the preset parameters, and after stripping the outer sheath, carefully check whether the wire is damaged, and whether the shielding layer and signal line protecting the inside are damaged. Finally, remove the stripped waste and properly place the wire that has been stripped of the outer sheath to prepare for the next step, and ensure that the size is controlled within the requirement of 28+ / -2mm;

[0068] S3: Cut braiding, ensure that the HDMI cables to be processed are arranged neatly, and prepare space for the processed cable segments. According to the specific specifications, diameter, and material of the HDMI cables, adjust the relevant cutting depth of the wire stripping machine to ensure that only the braided layer is cut without damaging the internal wires. Determine the length of the outer sheath to be stripped and the braided layer to be cut. Put the HDMI cable correctly into the fixture of the wire stripping machine / cutter braiding machine, ensure that the wire is stable and motionless, press the start button, and let the machine work according to the preset parameters. After the cutting and braiding process is completed, carefully check whether the wire is damaged, and avoid protecting the internal shielding layer and signal line from damage. After the braiding is even, turn it over and cut it cleanly, and keep the ground wire;

[0069] S4: Cut the aluminum foil manually using aluminum foil scissors or utility knife. Since aluminum foil easily generates static electricity and absorbs dust, an electrostatic eliminator is required during the processing of the aluminum foil. The operator tears off one end of the aluminum foil to separate it from the HDMI cable. Use special aluminum foil scissors or utility knife to trim the aluminum foil layer along the required length, keeping the edges neat to avoid cutting the internal wires. Then use a dust-free cloth or air gun to clean off any remaining small pieces of aluminum foil to prevent it from entering between the internal wires. Finally, check whether all the aluminum foil is neatly cut and there is no residue adhering to the internal wires. Arrange the wires for the next step.

[0070] S5: Laser cutting & removing aluminum foil Mylar. Use a laser cutting machine to remove aluminum foil Mylar. The laser cutting machine can achieve fine processing of different materials by controlling the energy, speed and focal position of the laser beam. A vacuum adsorption platform is used to fix the wire to ensure that the wire will not move during the laser cutting process, thereby ensuring cutting accuracy. Adjust the relevant parameters of the laser cutting machine, including laser power, scanning speed, and frequency, to ensure that only the aluminum foil Mylar layer is cut without damaging the internal wires. Then start the laser cutting machine and work according to the preset parameters. The laser will cut the aluminum foil Mylar layer along the set path without damaging the shielding layer and signal line below. After the process is completed, carefully check the cut wire to ensure that the internal structure is not damaged.

[0071] S6: Put 2 sleeves on both ends, use a hot air gun or heat shrink oven to shrink the sleeves to make them fit tightly against the cable and connector, remove impurities on the cable surface, and properly place the processed wires to prepare for the next step. Then select the appropriate size of sleeve according to the cable diameter and pre-cut it into appropriate lengths as needed. First slide the sleeve over one end of the HDMI cable until it is in a position that will not hinder subsequent operations. When the components are assembled, slide the sleeve to the predetermined position, covering the root of the connector and the end of the cable. Check whether the sleeve completely covers the expected area and the appearance is neat and not reversed; then organize the wires for the next step;

[0072] S7: Two aluminum caps are inserted on both sides in the middle. The purpose of inserting aluminum caps on both sides in the middle is to enhance the electromagnetic shielding performance and mechanical protection of the cable. Select the aluminum caps of appropriate sizes by manually installing the aluminum caps, and check their quality in advance as needed. Use appropriate cleaning tools to clean the surface of the cable to ensure that there is no dust or other impurities that affect the installation of the aluminum caps. Put the aluminum caps into the HDMI cable at the specified position to ensure that they are in the correct position. Use crimping pliers to crimp the aluminum caps to ensure that they fit the cable firmly and keep the crimping uniform to avoid damaging the internal structure of the cable. Then carefully check whether the aluminum caps are correctly installed and ensure that they are not skewed or loose.

[0073] S8: A yellow protective net is placed in the middle. The protective net is a braided net or winding tube. Its function is to enhance the mechanical strength of the cable and provide additional electromagnetic shielding. An automatic braiding machine or winding machine is used to adjust the braiding density and winding spacing. The yellow protective net is braided or wound at the specified position to ensure that it covers the entire area to be protected. The braiding or winding process is completed automatically to ensure that the yellow protective net fits firmly. After the process is completed, carefully check whether the yellow protective net covers the cable evenly and tightly to ensure that there is no looseness or unevenness. Trim the excess part to achieve the ideal length and appearance. The wires that have completed the installation of the yellow protective net are properly placed to prepare for the next process.

[0074] S9: Cable arrangement*4. Cable arrangement is to arrange and fix multiple strands of internal wires in a specific order to ensure the quality and stability of signal transmission. An automatic cable arrangement machine is used to quickly and accurately arrange multiple strands of wires in a predetermined order and fix them. A microscope or magnifying glass is used to check the cable arrangement quality. A vernier caliper or micrometer is used to ensure the accuracy of the wire arrangement. A welding or crimping tool is used to fix the arranged wires to the connector terminals. The working area and cable surface are cleaned to ensure that there is no dust or other impurities that affect the cable arrangement quality. Then the wires are sorted and the wires that have been arranged and fixed are properly placed to prepare for the next step.

[0075] S10: Double stripping*4, through the double stripping process, the same wire is stripped twice at different positions. This process is used to separate the shielding layer and the signal line, or to prepare for the installation of the connector. The double stripping operation is completed by an automatic double stripping machine. During the double stripping sample inspection, a microscope or magnifying glass is used to check the quality after double stripping, and then the start button is pressed to let the machine perform the first stripping according to the preset parameters, and then move to the specified position for the second stripping. The core stripping size is 2+ / -0.5mm, and the core wire cannot be damaged;

[0076] The first stripping is to cut the outer sheath at the designated position, carefully peel off the outer sheath to expose the internal structure, and the second stripping is to move to another designated position, repeat the above steps for the second stripping operation, and properly place the processed wires to prepare for the next step;

[0077] S11: Tinning*4. The tinning process is to improve the conductivity, prevent oxidation and facilitate subsequent welding. The ends of the internal multi-strand wires are tinned. A manual soldering iron and tin wire are used in a tin furnace. The flux is applied by a flux coating device before tinning to ensure that the tin can be evenly attached. After cleaning the flux residue, manual tinning is performed by a tin furnace to ensure the cleanliness after tinning. After tinning, the wire is moved to the cooling area and waited for natural cooling or a cooling device is used to accelerate the cooling process. After the process is completed, the excess tin slag is removed and the treated wire is properly placed to prepare for the next process.

[0078] S12: Installing the plug*4. Installing the plug means installing the connector. This process directly affects the function and quality of the finished cable. The terminal of the HDMI connector is crimped together with the internal wire through an automatic terminal crimping machine. The crimping makes the direction of the wire clamp consistent. The HDMI connector assembly equipment is used to fix the connector shell, insert the terminal, connect the shielding layer or the part that needs to be welded through an ultrasonic welding machine, and then use a continuity tester or a tension tester to ensure the electrical performance and mechanical strength of the connector after installation. After the strength test, the shell of the HDMI connector is put in and fixed with a screwdriver or other tools to ensure that it fits the cable tightly to ensure its normal operation.

[0079] S13: High-frequency welding*4. High-frequency welding is ultrasonic welding or high-frequency induction welding. The high-frequency current of the high-frequency welding machine generates heat to achieve fast and precise welding. The HDMI cables to be processed are neatly arranged, and space for the processed cable segments is prepared. After welding, the cables are moved to the cooling area and wait for them to cool naturally or use a cooling device to accelerate the cooling process. The welding points are carefully checked to ensure that the welding is firm and there is no false welding or over-welding to ensure its normal operation.

[0080] S14: Solder joint inspection*4. Solder joint inspection is a key step to ensure welding quality, electrical performance and mechanical strength. An ultrasonic detector is used to detect whether there are cold joints or bubbles inside the solder joints. The inspection results are recorded manually to mark unqualified solder joints. For solder joints marked as unqualified, they are carefully inspected and necessary repairs are made to ensure that they meet the quality standards. Then a tensile tester is used to apply a certain tensile force to the solder joints to ensure that they can withstand the specified force without falling off. The wires that have been inspected and repaired are properly placed to prepare for the next step.

[0081] S15: Test semi-finished products*2. This process uses a wire comprehensive tester to test the electrical conditions according to the drawings. The tests include continuity test, insulation resistance test, and withstand voltage test. The results are manually tested and unqualified items are marked. For cables marked as unqualified, they are carefully inspected and necessary repairs are made to ensure that they meet the quality standards. The cables that have been tested and repaired are properly placed to prepare for the next process.

[0082] S16: Use a 2.0T vertical molding machine to mold the inner molds at both ends of the cable. There must be no glue missing during molding.

[0083] S17: Form the middle aluminum mold using a 2.0T vertical molding machine. The inner molds at both ends of the cable must not be lacking in glue.

[0084] S18: Second test: 2 semi-finished product inner molds, use wire comprehensive testing machine to test according to the electrical conditions of the drawing, record the test results manually, mark the unqualified solder joints, carefully check and make necessary repairs for the solder joints marked as unqualified to ensure that they meet the quality standards, and properly place the wires that have been tested and repaired to prepare for the next process;

[0085] S19: Use a 2.0T vertical molding machine to form the middle mold at both ends of the cable. There must be no glue missing during the inner mold molding at both ends of the cable.

[0086] S20: Use a 2.0T vertical molding machine to mold the outer molds at both ends of the cable. There must be no glue missing when molding the inner molds at both ends of the cable.

[0087] S21: The aluminum mold in the middle is formed using a 2.0T vertical forming machine. The inner molds at both ends of the cable must be formed without any glue missing.

[0088] S22: Assemble the amplifier, weld the amplifier module to the internal wires of the HDMI cable, fix the amplifier housing and insert the circuit board, align the amplifier module with the HDMI cable at the specified position and fix it on the cable, use an automatic welding machine or manual welding tools to accurately weld the pins of the amplifier module to the internal wires of the HDMI cable, ensure that each wire corresponds to the correct pin, then put the housing of the amplifier module in and fix it with a screwdriver or other tools, ensure that it fits the cable tightly and does not affect the internal connection, use a signal generator and an oscilloscope to perform a functional test on the amplifier to ensure that it can correctly amplify and transmit HDMI signals, and pay attention to the direction of the input and output ends of the amplifier;

[0089] S23: Test of semi-finished products. Use wire comprehensive testing machine to test according to the electrical conditions of the drawing. This process adds an amplifier test. Pay attention to the direction of the amplifier's inlet and outlet during the test.

[0090] S24: Assemble the copper tube. This step is used to enhance the mechanical strength of the cable, provide additional electromagnetic shielding, and serve as a supporting structure inside the heat shrink tubing. An automatic copper tube insertion machine is used to insert the copper tube into the specified position of the HDMI cable. When checking the quality, it is necessary to check whether the copper tube is correctly inserted into place to ensure that it fits firmly into the internal structure of the cable and does not affect other components.

[0091] S25: Install the hexagonal screws. Prepare the hexagonal screws, washers and nuts, and check their status in advance as needed. Find the screw holes at the designated locations and make sure they match the hexagonal screws. Use a manual screwdriver or torque wrench to screw the hexagonal screws into the screw holes and make sure they can go in smoothly.

[0092] S26: Put on the yellow protective net, the outer layer is a woven net or a winding tube, start weaving or winding the yellow protective net at the designated position to ensure that it covers the entire area to be protected, and then trim the excess part to achieve the ideal length and appearance, and properly place the wires that have been installed with the yellow protective net to prepare for the next step;

[0093] S27: Finished product testing, using a wire comprehensive testing machine to test the electrical conditions according to the drawings, manually record the test results, mark the unqualified records, check the corresponding component structures of the records marked as unqualified and make necessary repairs to ensure that they meet the quality standards, and properly place the wires that have been tested and repaired to prepare for the next process;

[0094] S28: Audio and video test. Testing with a 4K TV and a signal source can simulate actual usage scenarios and verify whether the HDMI cable can stably transmit high-definition audio and video signals. Prepare a 4K ultra-high-definition TV that supports HDMI 2.0 or above in advance, and prepare a 4K signal source device in advance. The 4K signal source device includes a Blu-ray player, a 4K streaming box, a game console, or a dedicated HDMI signal generator. During the test, ensure that the light in the test environment is moderate to avoid excessive or weak light affecting visual judgment and external noise interfering with the audio test. Connect the signal source to the HDMI cable, connect the HDMI output port of the 4K signal source device to one end of the HDMI cable to be tested, and insert the other end of the HDMI cable to be tested into the HDMI input port of the 4K TV. Turn on the 4K TV and select the correct HDMI input channel. Turn on the signal source device and ensure that it is set to 4K resolution output.

[0095] Select a high-quality 4K video content on the signal source device and play it. Pay attention to whether there is any abnormality in the picture on the TV screen, whether the image clarity and color reproduction are normal, whether there is any picture freeze, frame drop or flicker, whether there is obvious image noise or distortion, and use the TV menu to confirm whether the current displayed resolution and refresh rate reach 4K and 60Hz;

[0096] Pay attention to whether there is any abnormality in the audio, whether the sound is clear, whether the stereo effect is good, whether there is audio delay or synchronization problem, whether there is popping sound, noise or abnormal sound, record the results of each test, including the type of signal source used, the content played, and the phenomenon observed. After the test is correct, properly place the HDMI cable that has passed the test and prepare for the next process;

[0097] S29: Blowing the sleeve. In this step, a hair dryer is used to put the sleeve on the surface of the cable. The sleeve is shrunk by blowing hot air with temperature through the hair dryer. After the process is completed, it is tested to ensure that the wire is not damaged by the blow. The qualified HDMI cable is properly placed to prepare for the next process.

[0098] S30: labeling. This step is done manually and the label cannot be pasted upside down.

[0099] S31: Appearance inspection, use a utility knife to trim the sharp edges or burrs, and pay attention to the printing direction. There should be no glue missing;

[0100] S32: Wire winding & Velcro binding. This step involves manual wire winding according to the drawing requirements. The wire winding consists of three turns in one bundle. The wire winding is assisted by a winding reel or a winding board. After the wire winding is completed, the wire is moved to the binding table and assisted by a Velcro binding fixture. The Velcro tape is then wrapped around the cable at the designated position to ensure that it fits tightly but not too tight to avoid damaging the cable.

[0101] S33: Finished product testing, using a wire comprehensive testing machine to test the electrical conditions according to the drawings, manually record the test results, mark the unqualified records, check the corresponding component structures of the records marked as unqualified and make necessary repairs to ensure that they meet the quality standards, and properly place the wires that have been tested and repaired to prepare for the next process;

[0102] S34: Check and clean the hardware. Sampling is used for testing. The wires must not be dirty or crushed by the hardware. The corresponding component structures marked as unqualified are checked and reported.

[0103] S35: Installing a protective cover, which is a heat shrink protective cover. In this step, a hair dryer is used to put the protective cover on the surface of the cable, and hot air is blown out by the hair dryer to shrink the protective cover. After the process is completed, an inspection is performed to ensure that the wire is not damaged by the blow, and the qualified HDMI cable is properly placed to prepare for the next process;

[0104] S36: Full inspection of appearance & cleaning of wire / bagging,

[0105] The inspection is carried out by sampling the appearance of the whole inspection. Cleaning is carried out with a dust-free cloth or a special cleaning cloth, an air gun or a compressed air tank. The cleaning agent is isopropyl alcohol. Wipe the cable material under the premise of ensuring its safety. After wiping, use an electrostatic eliminator to prevent static electricity from absorbing dust. After the process is completed, bagging is carried out. Antistatic bags or antistatic foam are used for bagging.

[0106] S37: Attach 69 label / attach SN anti-counterfeit label, use label printer to print 69 barcode label and SN anti-counterfeit label, and attach the label according to the drawing requirements;

[0107] S38: Fold color boxes / install certificates / install color boxes, use automatic folding machines to fold color boxes, prepare certificates and use label printers to generate certificates, ensuring that the information on each certificate is unique and meets the standards.

[0108] Make sure that the HDMI cable to be packed into the color box has completed all necessary pre-processing, including labeling and cleaning. Prepare all accessories, instructions, and warranty cards that need to be packed together and put them into the cable and accessories. Then carefully put the HDMI cable into the color box to ensure that it is not squeezed or twisted. Put all accessories that need to be packed together in order according to the pre-designed positions. Make sure that all items in the color box are complete and neatly arranged. Finally, use a heat sealer or tape sealer to seal the color box to ensure that it is firmly sealed to prevent moisture or contamination during transportation;

[0109] S39: Scan the barcode / check the barcode / external inspection. Use a barcode scanner to scan each label to ensure that its content is correct and matches the record in the database. Carefully check whether the label is correctly pasted in place, ensure that it is flat, free of bubbles, and skew, and that there are no missed scans. External inspection is carried out by sampling.

[0110] S40: Paste the outer box label, use the label printer to print the outer box label, and paste the label according to the drawing requirements;

[0111] S41: Packing / sealing / weighing, use a hot melt glue gun or tape sealer to seal the cartons, apply glue or tape evenly along the opening of the carton to ensure a firm seal, do not over or under pack, carefully check the sealed cartons to ensure they are structurally sound, neat in appearance, without damage or skew, confirm that the sealing materials are completely dry or firmly affixed to prevent the cartons from loosening or getting damp during transportation; place the sealed cartons on an electronic scale and record their weight, store the weighed and labeled cartons properly, and prepare for warehousing or shipment.

[0112] This embodiment uses multiple processes to cooperate to complete the manufacturing, testing, decoration, packaging and warehousing of HDMI cables. Through automated processes, labor costs are reduced, while the product quality rate is increased, and the need for outsourcing to factories in traditional processes is improved. This process improves the defects and outsourcing steps of existing processes, reduces the occurrence of management errors or increases in process time, improves work efficiency, and reduces the risk of process breakage. The product model of this embodiment is the HD101 series (60357 / 60358 / 60359), and the product description is HDMI AM TO AM gold-plated black round wire 25 to 30 meters. This embodiment 2:

[0113] The product model of this embodiment is HD101 series (10169 / 10170 / 10171 / 11106), and the product description is HDMIAM TO AM high-definition cable 8 to 15 meters. The process steps are shown in Table 1:

[0114]

[0115]

[0116] Table 1

[0117] This embodiment three:

[0118] The product model of this embodiment is the HD101 series (10151 / 10115 / 10128 / 10129 / 10130 / 10167), and the product description is HDMI AM TO AM high-definition cable 0.7-5 meters. The process steps are shown in Table 2:

[0119]

[0120]

[0121]

[0122] Table 2

[0123] The above contents are further detailed descriptions of the present invention in combination with specific preferred embodiments, and it cannot be determined that the specific implementation of the present invention is limited to these descriptions. For ordinary technicians in the technical field to which the present invention belongs, several simple deductions or substitutions can be made without departing from the concept of the present invention, which should be regarded as the protection scope of the present invention.

Claims

1. A HDMI cable production process, characterized in that: The process comprises the following steps: S1: Wire cutting & winding. During wire cutting, the wire is cut to the required length by an automatic wire cutter. After cutting, the wire stripper is used to remove the insulation layer at both ends of the wire to expose the internal metal conductor. Then, a wire winding machine or a wire twisting machine is used to twist the multiple strands of wire together in a specific way to ensure the quality of signal transmission. Finally, the terminal crimping machine is used to crimp the terminal of the HDMI connector and the internal wire together. The rolled HDMI wire is loaded into the automatic wire cutter, and the wire cutter parameters, including cutting length and quantity, are set. Then the machine is started to automatically complete the cutting and check whether the cut wire length meets the requirements. When winding or twisting the wires, you need to use a winding machine to twist them into a composite cable. Install each strand of wire correctly on the winding machine, set the winding direction and tightness according to the needs, start the winding process, ensure that the wires are closely arranged to reduce electromagnetic interference, and check the cable quality after winding to ensure that there is no uneven winding or loose areas. S2: Strip the outer sheath. Use the 315 horizontal stripping machine to accurately strip the outer sheath of the cable according to the set parameters. Arrange the HDMI cables to be processed neatly and prepare space for the processed cable segments. According to the specific specifications, diameter and material of the HDMI cable, adjust the relevant parameters of the wire stripping machine, cutting depth and length, correctly put the HDMI cable into the fixing device of the wire stripping machine, ensure that the wire is stable and immovable, press the start button to make the wire stripping machine work according to the preset parameters, and after stripping the outer sheath, carefully check whether the wire is damaged, and whether the shielding layer and signal line protecting the inside are damaged. Finally, remove the stripped waste and properly place the wire that has been stripped of the outer sheath to prepare for the next step; S3: Cut braiding, ensure that the HDMI cables to be processed are arranged neatly, and prepare space for the processed cable segments. According to the specific specifications, diameter, and material of the HDMI cables, adjust the relevant cutting depth of the wire stripping machine to ensure that only the braided layer is cut without damaging the internal wires. Determine the length of the outer sheath to be stripped and the braided layer to be cut. Put the HDMI cable correctly into the fixture of the wire stripping machine / cutter braiding machine, ensure that the wire is stable and motionless, press the start button, and let the machine work according to the preset parameters. After the cutting and braiding process is completed, carefully check whether the wire is damaged, and avoid protecting the internal shielding layer and signal line from damage. After the braiding is even, turn it over and cut it cleanly, and keep the ground wire; S4: Cut the aluminum foil manually using aluminum foil scissors or utility knife. Since aluminum foil easily generates static electricity and absorbs dust, an electrostatic eliminator is required during the processing of the aluminum foil. The operator tears off one end of the aluminum foil to separate it from the HDMI cable. Use special aluminum foil scissors or utility knife to trim the aluminum foil layer along the required length, keeping the edges neat to avoid cutting the internal wires. Then use a dust-free cloth or air gun to clean off any remaining small pieces of aluminum foil to prevent it from entering between the internal wires. Finally, check whether all the aluminum foil is neatly cut and there is no residue adhering to the internal wires. Arrange the wires for the next step. S5: Laser cutting & removing aluminum foil Mylar. Use a laser cutting machine to remove aluminum foil Mylar. The laser cutting machine can achieve fine processing of different materials by controlling the energy, speed and focal position of the laser beam. A vacuum adsorption platform is used to fix the wire to ensure that the wire will not move during the laser cutting process, thereby ensuring cutting accuracy. Adjust the relevant parameters of the laser cutting machine, including laser power, scanning speed, and frequency, to ensure that only the aluminum foil Mylar layer is cut without damaging the internal wires. Then start the laser cutting machine and work according to the preset parameters. The laser will cut the aluminum foil Mylar layer along the set path without damaging the shielding layer and signal line below. After the process is completed, carefully check the cut wire to ensure that the internal structure is not damaged. S6: Put 2 sleeves on both ends, use a hot air gun or heat shrink oven to shrink the sleeves to make them fit tightly against the cable and connector, remove impurities on the cable surface, and properly place the processed wires to prepare for the next step. Then select the appropriate size of sleeve according to the cable diameter and pre-cut it into appropriate lengths as needed. First slide the sleeve over one end of the HDMI cable until it is in a position that will not hinder subsequent operations. When the components are assembled, slide the sleeve to the predetermined position, covering the root of the connector and the end of the cable. Check whether the sleeve completely covers the expected area and the appearance is neat and not reversed; then organize the wires for the next step; S7: Two aluminum caps are inserted on both sides in the middle. The purpose of inserting aluminum caps on both sides in the middle is to enhance the electromagnetic shielding performance and mechanical protection of the cable. Select the aluminum caps of appropriate sizes by manually installing the aluminum caps, and check their quality in advance as needed. Use appropriate cleaning tools to clean the surface of the cable to ensure that there is no dust or other impurities that affect the installation of the aluminum caps. Put the aluminum caps into the HDMI cable at the specified position to ensure that they are in the correct position. Use crimping pliers to crimp the aluminum caps to ensure that they fit the cable firmly and keep the crimping uniform to avoid damaging the internal structure of the cable. Then carefully check whether the aluminum caps are correctly installed and ensure that they are not skewed or loose. S8: A yellow protective net is placed in the middle. The protective net is a braided net or winding tube. Its function is to enhance the mechanical strength of the cable and provide additional electromagnetic shielding. An automatic braiding machine or winding machine is used to adjust the braiding density and winding spacing. The yellow protective net is braided or wound at the specified position to ensure that it covers the entire area to be protected. The braiding or winding process is completed automatically to ensure that the yellow protective net fits firmly. After the process is completed, carefully check whether the yellow protective net covers the cable evenly and tightly to ensure that there is no looseness or unevenness. Trim the excess part to achieve the ideal length and appearance. The wires that have completed the installation of the yellow protective net are properly placed to prepare for the next process. S9: Cable arrangement*4. Cable arrangement is to arrange and fix multiple strands of internal wires in a specific order to ensure the quality and stability of signal transmission. An automatic cable arrangement machine is used to quickly and accurately arrange multiple strands of wires in a predetermined order and fix them. A microscope or magnifying glass is used to check the cable arrangement quality. A vernier caliper or micrometer is used to ensure the accuracy of the wire arrangement. A welding or crimping tool is used to fix the arranged wires to the connector terminals. The working area and cable surface are cleaned to ensure that there is no dust or other impurities that affect the cable arrangement quality. Then the wires are sorted and the wires that have been arranged and fixed are properly placed to prepare for the next step. S10: Double stripping*4, through the double stripping process, the same wire is stripped twice at different positions. This process is used to separate the shielding layer and the signal line, or to prepare for the installation of the connector. The double stripping operation is completed by an automatic double stripping machine. During the double stripping sample inspection, a microscope or magnifying glass is used to check the quality after double stripping, and then the start button is pressed to let the machine perform the first stripping according to the preset parameters, and then move to the specified position for the second stripping; The first stripping is to cut the outer sheath at the designated position, carefully peel off the outer sheath to expose the internal structure, and the second stripping is to move to another designated position, repeat the above steps for the second stripping operation, and properly place the processed wires to prepare for the next step; S11: Tinning*4. The tinning process is to improve the conductivity, prevent oxidation and facilitate subsequent welding. The ends of the internal multi-strand wires are tinned. A manual soldering iron and tin wire are used in a tin furnace. The flux is applied by a flux coating device before tinning to ensure that the tin can be evenly attached. After cleaning the flux residue, manual tinning is performed by a tin furnace to ensure the cleanliness after tinning. After tinning, the wire is moved to the cooling area and waited for natural cooling or a cooling device is used to accelerate the cooling process. After the process is completed, the excess tin slag is removed and the treated wire is properly placed to prepare for the next process. S12: Installing the plug*4. Installing the plug means installing the connector. This process directly affects the function and quality of the finished cable. The terminal of the HDMI connector is crimped together with the internal wire through an automatic terminal crimping machine. The crimping makes the direction of the wire clamp consistent. The HDMI connector assembly equipment is used to fix the connector shell, insert the terminal, connect the shielding layer or the part that needs to be welded through an ultrasonic welding machine, and then use a continuity tester or a tension tester to ensure the electrical performance and mechanical strength of the connector after installation. After the strength test, the shell of the HDMI connector is put in and fixed with a screwdriver or other tools to ensure that it fits the cable tightly to ensure its normal operation. S13: High-frequency welding*4. High-frequency welding is ultrasonic welding or high-frequency induction welding. The high-frequency current of the high-frequency welding machine generates heat to achieve fast and precise welding. The HDMI cables to be processed are neatly arranged, and space for the processed cable segments is prepared. After welding, the cables are moved to the cooling area and wait for them to cool naturally or use a cooling device to accelerate the cooling process. The welding points are carefully checked to ensure that the welding is firm and there is no false welding or over-welding to ensure its normal operation. S14: Solder joint inspection*4. Solder joint inspection is a key step to ensure welding quality, electrical performance and mechanical strength. An ultrasonic detector is used to detect whether there are cold joints or bubbles inside the solder joints. The inspection results are recorded manually to mark unqualified solder joints. For solder joints marked as unqualified, they are carefully inspected and necessary repairs are made to ensure that they meet the quality standards. Then a tensile tester is used to apply a certain tensile force to the solder joints to ensure that they can withstand the specified force without falling off. The wires that have been inspected and repaired are properly placed to prepare for the next step. S15: Test semi-finished products*2. This process uses a wire comprehensive tester to test the electrical conditions according to the drawings. The tests include continuity test, insulation resistance test, and withstand voltage test. The results are manually tested and unqualified items are marked. For cables marked as unqualified, they are carefully inspected and necessary repairs are made to ensure that they meet the quality standards. The cables that have been tested and repaired are properly placed to prepare for the next process. S16: Use a 2.0T vertical molding machine to mold the inner molds at both ends of the cable. There must be no glue missing during molding. S17: Form the middle aluminum mold using a 2.0T vertical molding machine. The inner molds at both ends of the cable must not be lacking in glue. S18: Second test: 2 semi-finished product inner molds, use wire comprehensive testing machine to test according to the electrical conditions of the drawing, record the test results manually, mark the unqualified solder joints, carefully check and make necessary repairs for the solder joints marked as unqualified to ensure that they meet the quality standards, and properly place the wires that have been tested and repaired to prepare for the next process; S19: Use a 2.0T vertical molding machine to form the middle mold at both ends of the cable. There must be no glue missing during the inner mold molding at both ends of the cable. S20: Use a 2.0T vertical molding machine to mold the outer molds at both ends of the cable. There must be no glue missing when molding the inner molds at both ends of the cable. S21: The aluminum mold in the middle is formed using a 2.0T vertical forming machine. The inner molds at both ends of the cable must be formed without any glue missing. S22: Assemble the amplifier, weld the amplifier module to the internal wires of the HDMI cable, fix the amplifier housing and insert the circuit board, align the amplifier module with the HDMI cable at the specified position and fix it on the cable, use an automatic welding machine or manual welding tools to accurately weld the pins of the amplifier module to the internal wires of the HDMI cable, ensure that each wire corresponds to the correct pin, then put the housing of the amplifier module in and fix it with a screwdriver or other tools, ensure that it fits the cable tightly and does not affect the internal connection, use a signal generator and an oscilloscope to perform a functional test on the amplifier to ensure that it can correctly amplify and transmit HDMI signals, and pay attention to the direction of the input and output ends of the amplifier; S23: Test of semi-finished products. Use wire comprehensive testing machine to test according to the electrical conditions of the drawing. This process adds an amplifier test. Pay attention to the direction of the amplifier's inlet and outlet during the test. S24: Assemble the copper tube. This step is used to enhance the mechanical strength of the cable, provide additional electromagnetic shielding, and serve as a supporting structure inside the heat shrink tubing. An automatic copper tube insertion machine is used to insert the copper tube into the specified position of the HDMI cable. When checking the quality, it is necessary to check whether the copper tube is correctly inserted into place to ensure that it fits firmly into the internal structure of the cable and does not affect other components. S25: Install the hexagonal screws. Prepare the hexagonal screws, washers and nuts, and check their status in advance as needed. Find the screw holes at the designated locations and make sure they match the hexagonal screws. Use a manual screwdriver or torque wrench to screw the hexagonal screws into the screw holes and make sure they can go in smoothly. S26: Put on the yellow protective net, the outer layer is a woven net or a winding tube, start weaving or winding the yellow protective net at the designated position to ensure that it covers the entire area to be protected, and then trim the excess part to achieve the ideal length and appearance, and properly place the wires that have been installed with the yellow protective net to prepare for the next step; S27: Finished product testing, using a wire comprehensive testing machine to test the electrical conditions according to the drawings, manually record the test results, mark the unqualified records, check the corresponding component structures of the records marked as unqualified and make necessary repairs to ensure that they meet the quality standards, and properly place the wires that have been tested and repaired to prepare for the next process; S28: Audio and video test. Testing with a 4K TV and a signal source can simulate actual usage scenarios and verify whether the HDMI cable can stably transmit high-definition audio and video signals. Prepare a 4K ultra-high-definition TV that supports HDMI 2.0 or above in advance, and prepare a 4K signal source device in advance. The 4K signal source device includes a Blu-ray player, a 4K streaming box, a game console, or a dedicated HDMI signal generator. During the test, ensure that the light in the test environment is moderate to avoid excessive or weak light affecting visual judgment and external noise interfering with the audio test. Connect the signal source to the HDMI cable, connect the HDMI output port of the 4K signal source device to one end of the HDMI cable to be tested, and insert the other end of the HDMI cable to be tested into the HDMI input port of the 4K TV. Turn on the 4K TV and select the correct HDMI input channel. Turn on the signal source device and ensure that it is set to 4K resolution output. Select a high-quality 4K video content on the signal source device and play it. Pay attention to whether there is any abnormality in the picture on the TV screen, whether the image clarity and color reproduction are normal, whether there is any picture freeze, frame drop or flicker, whether there is obvious image noise or distortion, and use the TV menu to confirm whether the current displayed resolution and refresh rate reach 4K and 60Hz; Pay attention to whether there is any abnormality in the audio, whether the sound is clear, whether the stereo effect is good, whether there is audio delay or synchronization problem, whether there is popping sound, noise or abnormal sound, record the results of each test, including the type of signal source used, the content played, and the phenomenon observed. After the test is correct, properly place the HDMI cable that has passed the test and prepare for the next process; S29: Blowing the sleeve. In this step, a hair dryer is used to put the sleeve on the surface of the cable. The sleeve is shrunk by blowing hot air with temperature through the hair dryer. After the process is completed, it is tested to ensure that the wire is not damaged by the blow. The qualified HDMI cable is properly placed to prepare for the next process. S30: labeling. This step is done manually and the label cannot be pasted upside down. S31: Appearance inspection, use a utility knife to trim the sharp edges or burrs, and pay attention to the printing direction. There should be no glue missing; S32: Wire winding & Velcro binding. This step involves manual wire winding according to the drawing requirements. The wire winding consists of three turns in one bundle. The wire winding is assisted by a winding reel or a winding board. After the wire winding is completed, the wire is moved to the binding table and assisted by a Velcro binding fixture. The Velcro tape is then wrapped around the cable at the designated position to ensure that it fits tightly but not too tight to avoid damaging the cable. S33: Finished product testing, using a wire comprehensive testing machine to test the electrical conditions according to the drawings, manually record the test results, mark the unqualified records, check the corresponding component structures of the records marked as unqualified and make necessary repairs to ensure that they meet the quality standards, and properly place the wires that have been tested and repaired to prepare for the next process; S34: Check and clean the hardware. Sampling is used for testing. The wires must not be dirty or crushed by the hardware. The corresponding component structures marked as unqualified are checked and reported. S35: Installing a protective cover, which is a heat shrink protective cover. In this step, a hair dryer is used to put the protective cover on the surface of the cable, and hot air is blown out by the hair dryer to shrink the protective cover. After the process is completed, an inspection is performed to ensure that the wire is not damaged by the blow, and the qualified HDMI cable is properly placed to prepare for the next process; S36: Full inspection of appearance & cleaning of wire / bagging, The inspection is carried out by sampling the appearance of the whole inspection. Cleaning is carried out with a dust-free cloth or a special cleaning cloth, an air gun or a compressed air tank. The cleaning agent is isopropyl alcohol. Wipe the cable material under the premise of ensuring its safety. After wiping, use an electrostatic eliminator to prevent static electricity from absorbing dust. After the process is completed, bagging is carried out. Antistatic bags or antistatic foam are used for bagging. S37: Attach 69 label / attach SN anti-counterfeit label, use label printer to print 69 barcode label and SN anti-counterfeit label, and attach the label according to the drawing requirements; S38: Fold color boxes / install certificates / install color boxes, use automatic folding machines to fold color boxes, prepare certificates and use label printers to generate certificates, ensuring that the information on each certificate is unique and meets the standards. Make sure that the HDMI cable to be packed into the color box has completed all necessary pre-processing, including labeling and cleaning. Prepare all accessories, instructions, and warranty cards that need to be packed together and put them into the cable and accessories. Then carefully put the HDMI cable into the color box to ensure that it is not squeezed or twisted. Put all accessories that need to be packed together in order according to the pre-designed positions. Make sure that all items in the color box are complete and neatly arranged. Finally, use a heat sealer or tape sealer to seal the color box to ensure that it is firmly sealed to prevent moisture or contamination during transportation; S39: Scan the barcode / check the barcode / external inspection. Use a barcode scanner to scan each label to ensure that its content is correct and matches the record in the database. Carefully check whether the label is correctly pasted in place, ensure that it is flat, free of bubbles, and skew, and that there are no missed scans. External inspection is carried out by sampling. S40: Paste the outer box label, use the label printer to print the outer box label, and paste the label according to the drawing requirements; S41: Packing / sealing / weighing, use a hot melt glue gun or tape sealer to seal the cartons, apply glue or tape evenly along the opening of the carton to ensure a firm seal, do not over or under pack, carefully check the sealed cartons to ensure they are structurally sound, neat in appearance, without damage or skew, confirm that the sealing materials are completely dry or firmly affixed to prevent the cartons from loosening or getting damp during transportation; place the sealed cartons on an electronic scale and record their weight, store the weighed and labeled cartons properly, and prepare for warehousing or shipment.

2. The HDMI cable production process according to claim 1, characterized in that: In S2, it is ensured that the size is controlled within the requirement of 28+ / -2mm.

3. The HDMI cable production process according to claim 1, characterized in that: In the above S10, the core stripping size is 2+ / -0.5mm, and the core wire must not be damaged.

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