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Cables out of common problems and countermeasures

Cables out of common problems and countermeasures

  • Categories:Company news
  • Author:
  • Origin:
  • Time of issue:2021-03-19 17:21
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Cables out of common problems and countermeasures

  • Categories:Company news
  • Author:
  • Origin:
  • Time of issue:2021-03-19 17:21
  • Views:
Information

one The electronic line

1. Rough surface:

A. Temperature is too low: the temperature is properly raised

B. PVC baking insufficient: according to the operation standard baking glue (time/temperature)

C. The nose pressure is too small: replace the long outer die in the corridor section and increase the number of retinal pieces

2. Dead glue coke:

A. PVC in the machine head for a long time to stay: when the longer stay time will be discharged

B. Extracting temperature is too high, high temperature exiting when shutdown in time to cool down

3. Re:

A. High temperature: adjust the head/eye mold temperature appropriately to increase the aperture of the outer eye (showing bright surface and numbness)

B. The outer mold is too large: replace the outer mold with a slightly smaller aperture to increase the extrusion temperature (the surface becomes numb and foggy)

4. Push out the surface with bubbles:

A. Push temperature too high: reduce the push temperature

B. PVC baking insufficient: increase the baking time

5. The surface is uneven:

A. Conductor surface dirty: too little oil, and proper preheating

B. Extrusion temperature is too high and bubble shape: reduce the extrusion temperature and reduce the distance between the sink and the head

6. PVC shrinkage/melting loss:

A. Conductor not preheated: preheater temperature should be adjusted appropriately (copper wire does not oxidize, but it should be hot)

B. Low head pressure/low temperature: when using the pressurized outer die, the head eye die temperature will be slightly increased

C. The tank is not hot water, the tension of the wire storage frame is too large: when the water is too hot, the tension of the wire storage frame should be reduced as far as possible

7. High temperature brittle insulation:

A. PVC baking is insufficient: change the specification and bake PVC in time

B. Detached when rapid cooling: water tank over hot water

8. Core shift:

A. Mold aperture is too large: replace the mold (inner mold is too small/outer mold is too large)

B. Mold not set: reset the mold

C. Improper distance between inner and outer molds: adjust the distance between inner and outer molds according to the principle of "near before far"

9. other

A. Bad appearance caused by jump: the inner and outer die is replaced with a slightly larger aperture

B. Insufficient PVC mixing causes slag accumulation in the outer eye: increase the extrusion temperature and reduce the distance between the outer die aperture and the inner and outer eye

C. Scratch: Scratch caused by the outer mold, replace the copper wire between the inner and outer eye mold: fold the mold to clean the inner and outer mold

Scratch of trough guide wheel storage rack: put the wire into the guide wheel, and replace the storage rack in time if damaged.

two Be outside line

1. Appearance shows finished grain

Winding pattern: A Too much pressure (the distance between the inner and outer die is too far) : the distance between the inner and outer die is about 2M/M in production. The outer mold is too small: the production of foreign and domestic mold should be selected than OD 0.1-0.3m /M of the outer mold

Braided pattern :A. The outer mold is too small: the too small eye mold causes bad appearance due to the high pressure, so the outer mold with A slightly larger aperture should be selected in the production (the specific aperture size depends on the actual production).

The braided wire generally requires good peeling, so when there is no special requirement, the braided wire is generally taken out with half air tube. For the braided wire that needs to be taken out with full type, the pressure of the machine head is too large and too small, which will cause bad appearance of the braided wire. In the production according to the actual situation of the inner and outer mold distance and the outer mold aperture is adjusted to solve the problem of appearance.

2. Over pink line, aluminum foil line bad appearance

The stand or fall of talcum powder directly affects the appearance of wire, reason talcum powder must be baked dry before use. In this way, talcum powder can be evenly distributed on the wire. In the production of semi-finished products, we must pass through the middle of the brush to avoid bad appearance due to too much powder. The outer mold is too small and the inner and outer mold is too close to lead to bad appearance. The appearance of aluminum foil line is debugged with braided line.

3. Bad outer peeling and core wire adhesion

(1) In the production of the extrusion head pressure is too large will cause poor peeling, extrusion as far as possible by increasing the external die aperture method to avoid excessive pressure. Secondly, the closer the sink to the head, the better. The maximum amount of water should be appropriate to achieve rapid cooling.

(2) Poor isolation leads to poor peeling, winding offset, loose weaving and other causes of external attached to the core wire resulting in poor peeling. In production, we should pay attention to the selection of the inner mold can not be too small (it is appropriate to use semi-finished products to slide easily through the eye mold).

(3) Too little powder causes poor peeling. In the production, it is difficult to peeling because of the moisture and too little powder of talcum powder. The talcum powder will be baked and dried in time before production. Add talcum powder in time during extrusion, and adjust the distance of the mold (reduce) when accelerating.

(4) Core wire bonding: Core wire bonding is generally because the melting point of the rubber is too low and the rubber is fused and glued together at high temperature. In the first section of production, maximum water should be put into the water tank to achieve rapid cooling. When necessary, release agent or over-powder should be released when stranded. When extradited by can also be used first off type agent and then powder.

(5) Some customers require high power of wire stripping. In actual operation, adjust the conditions according to customers' requirements.

4. Abnormal surface appearance

Rough (1) :

A. The outer die is too large, and the appearance of the outer die is too large or rough in production. At this time, the outer die with A slightly smaller aperture needs to be replaced

B. PVC is wet, and talcum powder is dried in advance according to the operation standard before starting the machine

C. PVC mixing is not good, increase the omentum, increase the adding temperature, choose the pressurized outer mold can solve the problem

(2) stripes:

A. Bright stripes, bright stripes on the surface caused by high temperature in the first/second section, lower the temperature in one/two sections

B. Fog streaks, the high temperature in the third/fourth section causes fog streaks on the surface, drop temperature in the third/fourth section

(3) side bright side fog: the head/eye mold temperature is high and the head/eye mold heating is not uniform, resulting in the appearance of the side bright and side fog. When this kind of phenomenon occurs, the temperature of the head and eye mold should be lowered in time, and the filter screen should be replaced (the number of pieces should be reduced). The external mold can be improved by selecting a slightly smaller external mold without corridor section.

(4) and needles:

A. The head/eye mold temperature is high, so reduce the temperature appropriately.

B. The PVC is wet and should be dried before starting the machine

5. Core shift

(1) the inner mold is too large: in order to make the appearance good, the inner mold with a slightly larger aperture is generally selected, but the inner mold is too large and prone to intermittent core deviation or high speed core deviation, so as to avoid the inner mold is too large in the production process

(2) The mould adjusting screw is not locked. After the center adjustment is OK, tighten the four mould adjusting screws in time and then start the machine normally

(3) In other aspects, the leakage of the head and the debris in the pipe will also cause the core deviation to be adjusted according to the actual situation in the production. For the core deviation, the careful implementation of the independent inspection can prevent the production of batch defects.

threee Other poor controls

1. Uneven size of D: improper artificial control, pay attention to abnormal acceleration and deceleration, tension of wire release frame and tension of wire retraction, abnormal measuring tools, etc.

2. Adjust the bad printing according to the bad printing situation and countermeasures

3. Scratch: replace the eye mold when the eye mold is scratched

It can be solved by timely adjustment of the scratch of the guide wheel and the wire storage frame

Slag accumulation in the outer eye will also cause scratches. The material should be replaced fundamentally. Secondly, the problem of scratches caused by slag accumulation in the outer eye can be solved by increasing the extrusion temperature and replacing the outer mold with a slightly smaller aperture (without corridor segment).

4, plastic burning

Plastic burning is a common quality defect in the process of plastic extrusion, and its attention shows as follows: high temperature display; There are a lot of smoke and strong stimulating smell in the die mouth of the machine head, and cracking sound when it is serious. The extruded plastic layer has coke; There are continuous bubbles at the joint of the glue; The main reasons for the generation of notes are:

1) The temperature control reaches the thermal degradation temperature of plastics;

2) the screw has not been cleaned for a long time, and the accumulated burnt matter is extruded with the molten plastic;

3) The heating or shutdown time is too long, so that the plastic in the barrel is heated for a long time and decomposed;

4) The temperature controller is out of control or out of alignment, resulting in high temperature decomposition;

5) The cooling system of the extruder is not opened, resulting in shear friction overheating of the material.

Therefore, in the process of extrusion should be strengthened to check whether the heating and cooling system is normal; Extrusion temperature should be set according to the process requirements and screw speed; Reasonable control of the temperature time, regular cleaning of the extrusion system.

5. Poor plasticization of extruder

In the above mentioned temperature control requirements have mentioned the plasticization problem, generally poor plasticization is mainly manifested as: extrusion cladding with toad skin like; The plastic surface is black, dull, and has small cracks; The extruded cladding layer has obvious thread seam in the laminating place. The main reasons are as follows:

1) Temperature control is too low, especially the nose part;

2) other plastic particles with different properties are mixed in the insulation or sheath material;

3) the screw plastic rotation is too fast, the plastic is not completely plasticized;

4) Plastics themselves have quality problems.

For the above reasons, attention should be paid to the rationality of extrusion temperature control; The quality name of the receiving material should be confirmed; Can not blindly pursue output and improve the extrusion speed; Strengthen raw material storage, especially in plastic drying process; Reasonable mold arrangement to enhance extrusion pressure and screw reflux.

6. There are pores or bubbles in the extruded layer section, which are mainly caused by:

1) Excessive temperature control (especially in the feeding section);

2) plastic moisture;

3) Long time parking, decomposed plastic is not removed clean;

4) High humidity in natural environment;

5) Excessive content of water or gasified matter in the cable core.

For the above reasons, the temperature of each section of the screw should be reasonably controlled; Predry the materials used in advance; Strict process operation requirements, improve the evaluation ability of plastic plasticization degree; Pay attention to the production environment and material storage conditions.

7, the extrusion size is not qualified, mainly manifested as core deviation; Jacket thickness or outer diameter out of tolerance; The main reasons are as follows:

Extrusion and traction speed is not stable;

1) The outer diameter of cable core changes too much;

2) Extrusion temperature is too high, resulting in the reduction of extrusion volume;

3) the impurities in the plastic are too much blocked in the filter screen to reduce the plastic flow;

4) the tension of the wire is not stable;

5) the selection of the die core is too large (extrusion) or the length of the die core bearing line area is too short and the core;

6) Improper selection of mold spacing;

7) the temperature of the extrusion head is not uniform;

8) The concentricity of the extrusion die is not adjusted well;

9) Excessively high inlet temperature makes it difficult to feed and affects the feed flow;

For the above reasons, the outer diameter of the sheath should be regularly measured and adjusted in time; Reasonable selection and adjustment of extrusion die; Pay attention to the tension change of the wire and release timely adjust; Temperature control shall be consistent with the specified requirements;

8. The bond strength of the longitudinal wrapping belt is not qualified, the main reasons are:

1) Extrusion temperature is too low;

2) overfilling of ointment and overflow;

3) The production line speed is too fast, so that the jacket is rapidly cooled;

4) The temperature of the hot water tank is too low and close to the die mouth;

5) The mold drawing ratio is too small, or the mold is unreasonable, so that it forms loose bale;

6) the melting point of the composite film with longitudinal cladding is too high;

According to the above reasons, attention should be paid to the requirements of mold allocation and adjustment should be made according to the cable core if necessary; Can not allow the jacket to be rapidly cooled to improve the bonding ability; Should not improve the setting ability of the sheath and reduce the head temperature too much; Pay attention to the amount of ointment filling, so that a thin layer can be scraped off by touching the cable core lightly with your finger.

9. The appearance of the extrusion is not qualified. The appearance of the extrusion is mainly shown as scratch on the surface of the extrusion layer. Coarse with trachoma or microcracks; Any defect caused by a lack of plasticization. The main reasons are as follows:

1) The selection of extrusion die sleeve is unreasonable. Too small to cause hemp pattern; Too large cause disjunction or loose extrusion;

2) there are impurities stuck in the extrusion die sleeve and scratch the surface of the sheath.

3) the heating temperature of the extrusion head is too high to cause roughness, or the temperature is too low to cause microcrack;

4) There is damage in the die sleeve sizing area;

5) The sheath is abraded in the sink;

Defects can be eliminated or prevented in production for the above reasons.

In actual production, in addition to the above defects and reasons, there are also problems such as line arrangement, longitudinal package overlapping width, shape of bamboo joints and so on. We observe and summarize more in the production, grasp the main and essence of the problem, will be readily solved, the cable quality level to do better.

1. Rough surface:

A. Temperature is too low: the temperature is properly raised

B. PVC baking insufficient: according to the operation standard baking glue (time/temperature)

C. The nose pressure is too small: replace the long outer die in the corridor section and increase the number of retinal pieces

2. Dead glue coke:

A. PVC in the machine head for a long time to stay: when the longer stay time will be discharged

B. Extracting temperature is too high, high temperature exiting when shutdown in time to cool down

3. Re:

A. High temperature: adjust the head/eye mold temperature appropriately to increase the aperture of the outer eye (showing bright surface and numbness)

B. The outer mold is too large: replace the outer mold with a slightly smaller aperture to increase the extrusion temperature (the surface becomes numb and foggy)

4. Push out the surface with bubbles:

A. Push temperature too high: reduce the push temperature

B. PVC baking insufficient: increase the baking time

5. The surface is uneven:

A. Conductor surface dirty: too little oil, and proper preheating

B. Extrusion temperature is too high and bubble shape: reduce the extrusion temperature and reduce the distance between the sink and the head

6. PVC shrinkage/melting loss:

A. Conductor not preheated: preheater temperature should be adjusted appropriately (copper wire does not oxidize, but it should be hot)

B. Low head pressure/low temperature: when using the pressurized outer die, the head eye die temperature will be slightly increased

C. The tank is not hot water, the tension of the wire storage frame is too large: when the water is too hot, the tension of the wire storage frame should be reduced as far as possible

7. High temperature brittle insulation:

A. PVC baking is insufficient: change the specification and bake PVC in time

B. Detached when rapid cooling: water tank over hot water

8. Core shift:

A. Mold aperture is too large: replace the mold (inner mold is too small/outer mold is too large)

B. Mold not set: reset the mold

C. Improper distance between inner and outer molds: adjust the distance between inner and outer molds according to the principle of "near before far"

9. other

A. Bad appearance caused by jump: the inner and outer die is replaced with a slightly larger aperture

B. Insufficient PVC mixing causes slag accumulation in the outer eye: increase the extrusion temperature and reduce the distance between the outer die aperture and the inner and outer eye

C. Scratch: Scratch caused by the outer mold, replace the copper wire between the inner and outer eye mold: fold the mold to clean the inner and outer mold

Scratch of trough guide wheel storage rack: put the wire into the guide wheel, and replace the storage rack in time if damaged.

two Be outside line

1. Appearance shows finished grain

Winding pattern: A Too much pressure (the distance between the inner and outer die is too far) : the distance between the inner and outer die is about 2M/M in production. The outer mold is too small: the production of foreign and domestic mold should be selected than OD 0.1-0.3m /M of the outer mold

Braided pattern :A. The outer mold is too small: the too small eye mold causes bad appearance due to the high pressure, so the outer mold with A slightly larger aperture should be selected in the production (the specific aperture size depends on the actual production).

The braided wire generally requires good peeling, so when there is no special requirement, the braided wire is generally taken out with half air tube. For the braided wire that needs to be taken out with full type, the pressure of the machine head is too large and too small, which will cause bad appearance of the braided wire. In the production according to the actual situation of the inner and outer mold distance and the outer mold aperture is adjusted to solve the problem of appearance.

2. Over pink line, aluminum foil line bad appearance

The stand or fall of talcum powder directly affects the appearance of wire, reason talcum powder must be baked dry before use. In this way, talcum powder can be evenly distributed on the wire. In the production of semi-finished products, we must pass through the middle of the brush to avoid bad appearance due to too much powder. The outer mold is too small and the inner and outer mold is too close to lead to bad appearance. The appearance of aluminum foil line is debugged with braided line.

3. Bad outer peeling and core wire adhesion

(1) In the production of the extrusion head pressure is too large will cause poor peeling, extrusion as far as possible by increasing the external die aperture method to avoid excessive pressure. Secondly, the closer the sink to the head, the better. The maximum amount of water should be appropriate to achieve rapid cooling.

(2) Poor isolation leads to poor peeling, winding offset, loose weaving and other causes of external attached to the core wire resulting in poor peeling. In production, we should pay attention to the selection of the inner mold can not be too small (it is appropriate to use semi-finished products to slide easily through the eye mold).

(3) Too little powder causes poor peeling. In the production, it is difficult to peeling because of the moisture and too little powder of talcum powder. The talcum powder will be baked and dried in time before production. Add talcum powder in time during extrusion, and adjust the distance of the mold (reduce) when accelerating.

(4) Core wire bonding: Core wire bonding is generally because the melting point of the rubber is too low and the rubber is fused and glued together at high temperature. In the first section of production, maximum water should be put into the water tank to achieve rapid cooling. When necessary, release agent or over-powder should be released when stranded. When extradited by can also be used first off type agent and then powder.

(5) Some customers require high power of wire stripping. In actual operation, adjust the conditions according to customers' requirements.

4. Abnormal surface appearance

Rough (1) :

A. The outer die is too large, and the appearance of the outer die is too large or rough in production. At this time, the outer die with A slightly smaller aperture needs to be replaced

B. PVC is wet, and talcum powder is dried in advance according to the operation standard before starting the machine

C. PVC mixing is not good, increase the omentum, increase the adding temperature, choose the pressurized outer mold can solve the problem

(2) stripes:

A. Bright stripes, bright stripes on the surface caused by high temperature in the first/second section, lower the temperature in one/two sections

B. Fog streaks, the high temperature in the third/fourth section causes fog streaks on the surface, drop temperature in the third/fourth section

(3) side bright side fog: the head/eye mold temperature is high and the head/eye mold heating is not uniform, resulting in the appearance of the side bright and side fog. When this kind of phenomenon occurs, the temperature of the head and eye mold should be lowered in time, and the filter screen should be replaced (the number of pieces should be reduced). The external mold can be improved by selecting a slightly smaller external mold without corridor section.

(4) and needles:

A. The head/eye mold temperature is high, so reduce the temperature appropriately.

B. The PVC is wet and should be dried before starting the machine

5. Core shift

(1) the inner mold is too large: in order to make the appearance good, the inner mold with a slightly larger aperture is generally selected, but the inner mold is too large and prone to intermittent core deviation or high speed core deviation, so as to avoid the inner mold is too large in the production process

(2) The mould adjusting screw is not locked. After the center adjustment is OK, tighten the four mould adjusting screws in time and then start the machine normally

(3) In other aspects, the leakage of the head and the debris in the pipe will also cause the core deviation to be adjusted according to the actual situation in the production. For the core deviation, the careful implementation of the independent inspection can prevent the production of batch defects.

3. Other poor controls

1. Uneven size of D: improper artificial control, pay attention to abnormal acceleration and deceleration, tension of wire release frame and tension of wire retraction, abnormal measuring tools, etc.

2. Adjust the bad printing according to the bad printing situation and countermeasures

3. Scratch: replace the eye mold when the eye mold is scratched

It can be solved by timely adjustment of the scratch of the guide wheel and the wire storage frame

Slag accumulation in the outer eye will also cause scratches. The material should be replaced fundamentally. Secondly, the problem of scratches caused by slag accumulation in the outer eye can be solved by increasing the extrusion temperature and replacing the outer mold with a slightly smaller aperture (without corridor segment).

4, plastic burning

Plastic burning is a common quality defect in the process of plastic extrusion, and its attention shows as follows: high temperature display; There are a lot of smoke and strong stimulating smell in the die mouth of the machine head, and cracking sound when it is serious. The extruded plastic layer has coke; There are continuous bubbles at the joint of the glue; The main reasons for the generation of notes are:

1) The temperature control reaches the thermal degradation temperature of plastics;

2) the screw has not been cleaned for a long time, and the accumulated burnt matter is extruded with the molten plastic;

3) The heating or shutdown time is too long, so that the plastic in the barrel is heated for a long time and decomposed;

4) The temperature controller is out of control or out of alignment, resulting in high temperature decomposition;

5) The cooling system of the extruder is not opened, resulting in shear friction overheating of the material.

Therefore, in the process of extrusion should be strengthened to check whether the heating and cooling system is normal; Extrusion temperature should be set according to the process requirements and screw speed; Reasonable control of the temperature time, regular cleaning of the extrusion system.

5. Poor plasticization of extruder

In the above mentioned temperature control requirements have mentioned the plasticization problem, generally poor plasticization is mainly manifested as: extrusion cladding with toad skin like; The plastic surface is black, dull, and has small cracks; The extruded cladding layer has obvious thread seam in the laminating place. The main reasons are as follows:

1) Temperature control is too low, especially the nose part;

2) other plastic particles with different properties are mixed in the insulation or sheath material;

3) the screw plastic rotation is too fast, the plastic is not completely plasticized;

4) Plastics themselves have quality problems.

For the above reasons, attention should be paid to the rationality of extrusion temperature control; The quality name of the receiving material should be confirmed; Can not blindly pursue output and improve the extrusion speed; Strengthen raw material storage, especially in plastic drying process; Reasonable mold arrangement to enhance extrusion pressure and screw reflux.

6. There are pores or bubbles in the extruded layer section, which are mainly caused by:

1) Excessive temperature control (especially in the feeding section);

2) plastic moisture;

3) Long time parking, decomposed plastic is not removed clean;

4) High humidity in natural environment;

5) Excessive content of water or gasified matter in the cable core.

For the above reasons, the temperature of each section of the screw should be reasonably controlled; Predry the materials used in advance; Strict process operation requirements, improve the evaluation ability of plastic plasticization degree; Pay attention to the production environment and material storage conditions.

7, the extrusion size is not qualified, mainly manifested as core deviation; Jacket thickness or outer diameter out of tolerance; The main reasons are as follows:

Extrusion and traction speed is not stable;

1) The outer diameter of cable core changes too much;

2) Extrusion temperature is too high, resulting in the reduction of extrusion volume;

3) the impurities in the plastic are too much blocked in the filter screen to reduce the plastic flow;

4) the tension of the wire is not stable;

5) the selection of the die core is too large (extrusion) or the length of the die core bearing line area is too short and the core;

6) Improper selection of mold spacing;

7) the temperature of the extrusion head is not uniform;

8) The concentricity of the extrusion die is not adjusted well;

9) Excessively high inlet temperature makes it difficult to feed and affects the feed flow;

For the above reasons, the outer diameter of the sheath should be regularly measured and adjusted in time; Reasonable selection and adjustment of extrusion die; Pay attention to the tension change of the wire and release timely adjust; Temperature control shall be consistent with the specified requirements;

8. The bond strength of the longitudinal wrapping belt is not qualified, the main reasons are:

1) Extrusion temperature is too low;

2) overfilling of ointment and overflow;

3) The production line speed is too fast, so that the jacket is rapidly cooled;

4) The temperature of the hot water tank is too low and close to the die mouth;

5) The mold drawing ratio is too small, or the mold is unreasonable, so that it forms loose bale;

6) the melting point of the composite film with longitudinal cladding is too high;

According to the above reasons, attention should be paid to the requirements of mold allocation and adjustment should be made according to the cable core if necessary; Can not allow the jacket to be rapidly cooled to improve the bonding ability; Should not improve the setting ability of the sheath and reduce the head temperature too much; Pay attention to the amount of ointment filling, so that a thin layer can be scraped off by touching the cable core lightly with your finger.

9. The appearance of the extrusion is not qualified. The appearance of the extrusion is mainly shown as scratch on the surface of the extrusion layer. Coarse with trachoma or microcracks; Any defect caused by a lack of plasticization. The main reasons are as follows:

1) The selection of extrusion die sleeve is unreasonable. Too small to cause hemp pattern; Too large cause disjunction or loose extrusion;

2) there are impurities stuck in the extrusion die sleeve and scratch the surface of the sheath.

3) the heating temperature of the extrusion head is too high to cause roughness, or the temperature is too low to cause microcrack;

4) There is damage in the die sleeve sizing area;

5) The sheath is abraded in the sink;

Defects can be eliminated or prevented in production for the above reasons.

In actual production, in addition to the above defects and reasons, there are also problems such as line arrangement, longitudinal package overlapping width, shape of bamboo joints and so on. We observe and summarize more in the production, grasp the main and essence of the problem, will be readily solved, the cable quality level to do better.

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