Jump Start Cable Production
Jump start cables that transfer energy from another vehicle to start an engine with a flat battery. Typically 10-50 mm² cross-section, PVC, PA6 or TPE insulation and copper crocodile clips.
Jump start cable production is one of the core product lines in the automotive sector. These cables transfer energy from another vehicle to start an engine when a battery has gone flat.
1. Design and material selection
- Cable diameter and length: chosen according to current capacity. Cables between 10 and 50 mm² are generally preferred.
- Insulation material: high-strength materials such as PVC, PA6 or TPE.
- Clamps (crocodile clips): copper materials with high conductivity are used.
2. Raw material supply
- Copper or aluminium conductors: used to carry the electrical current.
- Insulation jacket: quality materials are sourced for a covering that withstands external influences.
3. Production
Cable manufacture
Copper wires are brought together at the specified diameter and stranded. The insulation material is extruded onto the outer surface of the cable.
Clamp assembly
Crocodile clips are attached to the cable ends, usually by screwing, soldering or crimping.
Testing and quality control
Electrical tests measure the current capacity, resistance and insulation properties of the cable. Mechanical tests check durability, flexibility and the grip of the clamps.
4. Packing and labelling
Cables are packed together with usage instructions and safety warnings. Labelling states the technical properties of the product and its conformity to standards.
5. Conformity to standards
Jump start cables must be produced in line with international standards such as CE, RoHS and ISO 6722.
- 10-50 mm² cross-section range
- PVC, PA6 or TPE insulation
- Copper crocodile clips
- CE, RoHS and ISO 6722