Large CrossSection DC Charging Pile HighVoltage Cable Stripping Machine
Stripping large crosssection, highvoltage charging gun cables is far more challenging than working with ordinary wires. Therefore, equipment selection must be handled with extra care.
1. Key Challenges
When it comes to DC charging gun highvoltage cables (large squaremm conductors), several major technical challenges need to be considered:
1. Large Cable Diameter
Highvoltage charging cables typically have a large conductor crosssection and thick outer diameter.
Standard wire stripping machines often struggle with feeding, clamping, and cutting, resulting in difficult processing or damaged conductors.
As Assembly Magazine notes, “Processing largediameter cables requires powerful feeding and drive mechanisms.”
If the clamping force is insufficient or the cutter angle is misaligned, the insulation may not be completely removed—or worse, the copper strands may be scratched.
2. Thick Insulation Layer
These highvoltage cables usually feature thick insulation and multilayer sheathing (e.g., XLPE, multicomposite layers, shielding + outer jacket).
The stripping process must adapt the cutting depth, method (rotary cut, longitudinal cut), and multistep peeling strategy accordingly.
Thick insulation is elastic and resistant, which can cause standard blades to deform or fail to cut through completely.
3. Risk of Copper Damage and High Conductivity Requirements
Under highvoltage and highcurrent operation, even a slight nick on a copper conductor or residual insulation can lead to increased resistance, localized heating, and reduced reliability.
Precision stripping is therefore essential — the insulation must be cleanly removed, the copper strands undamaged, and the strip length perfectly accurate.
4. Feeding, Clamping, and Stability Issues
Largediameter cables are stiff and heavy, making consistent feeding and alignment difficult.
They can easily slip, misalign, or shift under cutting pressure.
Cables with shielding or armor layers require machines that can handle high mechanical rigidity.
5. MultiStage Stripping and Process Flexibility
Charging cables often require multistage stripping — such as outer jacket removal, shielding peel, and insulation stripping.
If the equipment only supports singlestage operations, it limits flexibility.
Therefore, machines must allow for programmable stripping sequences with quick tool adjustments to accommodate various processes.
6. Efficiency and Consistency Requirements
In mass production, consistency of stripping length and quality is critical.
Any deviation may cause downstream connection problems (e.g., crimping or overmolding defects).
Automated stripping machines significantly improve stability, repeatability, and throughput.
2. Recommended Stripping Machine Types and Specifications
Large CrossSection DC Charging Pile HighVoltage Cable Stripping Machine
To handle largesquare, highvoltage DC charging cables, the ideal stripping machine should meet the following specifications:
Support for large crosssection / large outerdiameter cables (≥ 50 mm²; outer diameter up to 20–50 mm or larger)
Heavyduty feeding system — wide belts or strong clamps, hightorque feeding motors, and pressuremarkfree wire feeding
Rotary + longitudinal cutting system — for multilayer sheaths, shielding, or armored structures
Multistage stripping capability — programmable stripping for sheath, shield, and insulation layers
Touchscreen and digital control — for easy parameter setting, faster changeovers, and higher efficiency
Adjustable, durable cutting tools — quickchange blades and bearings designed for high wear resistance under heavy loads
Enhanced safety protection — essential when processing highvoltage cables
