How an electrical cable is made?

How an electrical cable is made?

The technology needed to ensure an electrical cable stays in good working condition for several years without problems involves complicated manufacturing processes.

Conductor: Wire DrawingThe first manufacturing process of a conductor is the wire-drawing. This consists of reducing the diameter of the copper wire gradually to its final diameter to increase its ductility and conductivity.Conductor: Wire DrawingThe copper arrives from the foundry in large coils weighing 5 tons. This copper, 8 mm in diameter, is technically known as wire rod.

Conductor: Wire DrawingThe first stage of the wire-drawing is simply called, drawing. The diameter of the wire rod is reduced to 2 mm during this process.

Conductor: Wire DrawingThis 2 mm wire is then drawn further to reduce the diameter of the wire to the size needed for each kind of conductor.

Conductor: Wire DrawingIn the last stage of wire-drawing, all the wires undergo a heat treatment called annealing. The aim of this stage is to increase the ductility and conductivity of the copper.

Conductor: WiringAfter the wire-drawing, the copper wires are grouped together to make conductors. This process is called wiring.

Conductor: WiringDuring the wiring process, conductors with different cross-sections are made. Its depends of the current capacities.

Conductor: WiringThe machine used to make the cables depends on the cross-section of each conductor.

INSULATIONThe next process in the manufacture of electrical cables is the insulation. This is when we place an insulating cover over the conductor to prevent current leakages. Different insulation materials may be used depending on the characteristics of the cable required. The quality of an insulation material depends on two basic characteristics: its insulation capacity and its heat resistance.

INSULATIONThe materials insulation capacity and its thickness determine the cables maximum service voltage. An insulation material with a high heat resistance allows the conductor to transmit more power than the same cross-section with an insulation with a lower heat resistance.

INSULATIONIn this process, the insulating material is added by a process of extrusion at high temperature. The insulation ensures there are no current leakages. Several insulating materials may be used: PVC, EPR, XLPE, etc.

INSULATIONA voltage test is made to ensure the insulation layer does not have any faults.

PHASE WIRINGPhase wiring is the grouping of different insulated conductors to make a multicore cable. The phases can be identified by color or by numbering them.

ADDITIONAL COVERINGSAnd that is how an electrical cable is made. In some cases, the cable may require additional elements in order to improve its protection or operation. Electrical coverings, also called screens, insulate the signals that circulate in the cable from possible external interference. They also shield the power cables to prevent them from interfering with adjacent signal circuits.

ADDITIONAL COVERINGSMechanical coverings, also called armour, protect the cable from external damage that may occur from knocks, rodents, and any other potential causes of damage. The armour is made from steel or aluminium and can come in the form of metal strips, wires or braids.

OUTER SHEATHCables usually have an outer polymer covering for protection. This is called the outer-sheath. This sheath protects the conductors and their insulation from external elements.