Electric Cables

 We are surrounded by electrical cables. We have become so used to it that

we hardly notice them. However, if we didn't have them, daily tasks such as
switching on a light in a room, using a lift, or turning on a computer
wouldn't be possible. The cables come in different types and sizes, which
makes it possible to supply electricity to this printer, or make a wind-turbine
work.
 The technology needed to ensure an electrical cable stays in good working
condition for several years without problems involves complicated
manufacturing processes which require highly qualified staff.11
Manufacturing of Electric Cables
 It mainly contains this things:

1. Conductor
2. Insulation
3. Screening if required
4. Assembly
5. Inner covering
6. Armoring
7. Outer sheath
8. Quality control
9. Shipping
10.Sustainability
 Conductor :
The basic components of an electrical cable are the conductor and the insulation.
The conductor channels the current through the cable and the insulation maintains
the flow of electricity in the conductor. Cables may also have other additional
coverings to protect them and increase their working life.
The most frequently used material for the conductor in an electrical cable is
copper. Aluminium is also used in specific cases.

 Wire Drawing process:

Wire drawing is a metal working process used to reduce the cross-section of

a wire by pulling the wire through a single, or series of, drawing diameter.
There are many applications for wire drawing, including electrical wiring,
cables, tension-loaded structural components, springs, paper clips, spokes
for wheels, and stringed musical instruments. Although similar in process,
drawing is different from extrusion, because in drawing the wire is pulled,
rather than pushed, through the die. Drawing is usually performed at room
temperature, thus classified as a cold working process, but it may be
performed at elevated temperatures for large wires to reduce forces.
The 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 and decrease the skin effect .The copper
arrives from the foundry to the manufacturer's factories in large coils weighing 5
tones .This copper, 8 mm in diameter, is technically known as "wire rod".
The first stage of the wire-drawing is simply called, "drawing". The diameter of the
wire rod is reduced to 2 mm during this process.
This 2-mm wire is then drawn further to reduce the diameter of the wire to the size
needed for each kind of conductor.

 Annealing:
In 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 as in drawing stages cooper loss some of its
 conductivity during reducing the diameter from 8 mm to the specified wire
diameter.

 Stranding:

After the wire-drawing, the copper wires are grouped together to make conductors.
This process is called stranding.
During the wiring process, conductors with different cross-sections are made. For
example, a cross-section as small as 0.5 mm2 to 240 mm2, 400 mm2 or even higher
for larger current capacities.
The machine used to make the cables depends on the cross-section of each
conductor.\

 Insulation:
The 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.
In 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.
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.
The material's insulation capacity and its thickness determine the cable's 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.
The whole length of the cable undergoes a voltage test to ensure the insulation
layer does not have any faults.
  Phase wiring:
Phase wiring is the grouping of different insulated conductors to make a
multicore cable on assembly machines.
The phases can be identified by color or by numbering them, check HD standard
HD 308 for colors and IEC 60502.
 Screens:
However, 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.
 Armor:
Mechanical coverings, also called "armor", protect the cable from external damage
that may occur from knocks, rodents, and any other potential causes of damage
.The armor is made from steel or aluminum and can come in the form of metal
strips, wires or braids.
 Outer Sheath:
Cables 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 which may change their electrical properties, such as moisture. It
also protects them from mechanical aggression, which may occur during the
installation of the cable.
As with the insulation, the outer-sheath can be made from a thermoplastic or a
thermosetting plastic.
The outer-sheath is applied like the insulation via a process of extrusion at high
temperature. The sheath may be made from different materials depending on the
required protection level, the final flexibility of the cable, the work environment,
etc. As example: PVC, LLDPE, MDPE, HDPE, LSHF, EPR, etc.
So that all Top Cable customers can correctly identify their cables, the cables are
marked with the most important information: Manufacturer, trade name, cable
name, number of conductors, cross-section, construction regulation and standards,
CE marking and other information of interest, such as the product's certification.
There is also a meter by meter mark on the cable to help our customers with their
stock control.
A voltage test is also carried out on the whole length of the manufactured cable
during this process.

And that is how an electrical cable is manufactured. But the process does not finish
here. The manufacturer verifies the quality of all cables by carrying out rigorous
checks before they are sold.
In order to guarantee the high quality required by Top Cable's customers, the
cables undergo extensive quality control checks in our laboratories, therefore
ensuring that all the cables are free from defects and are ready to be sold and this
according to each type and international standards IEC 60502-1, IEC 60227, BS
6004, ..etc.
The quality guarantee systems, approved according to the ISO 9001 regulation are
applied during all the manufacturing stages and guarantee that the cables will work
perfectly.

Orders are managed at our different logistics centres and then they are shipped out
to our customers. Our advanced Warehouse Management System (WMS) provides
us with information about the stock status at Top Cable's logistics centres at all
times, guaranteeing the availability of the product and allowing us to meet the
tightest deadlines.
We have created recycling systems at all Top Cable's manufacturing centres for the
waste produced during the manufacture of electrical cables.
All waste, both from scrap cable and waste produced during the manufacturing
process is delivered to specialized companies to be correctly disposed of. This is
how we guarantee that the environmental impact of our industrial activity is kept to
a minimum.

Different Tests carried out on the wires after manufacturing:

1. Persulphate test (for copper )

2. Annealing test (for copper)
3. Tensile test (for Aluminium)
4. Wrapping test (for Aluminium)
5. Conductor resistance test (for all)
6. Test of thickness of insulation (for all)
7. Measurement of overall diameter.

 Physical tests for insulation and sheath

1. Tensile strength and elongation at break
2. Ageing in air oven
3. Ageing in air bomb
4. Ageing in oxygen bomb
5. Hot set
6. Oil resistance
7. Tear resistance
2. Insulation resistance
3. High voltage (water immersion) test
4. Flammability test (only for SE-3, SE-4)
5. Water abortion test (for insulation)

 Acceptance test: The following shall constitute acceptance test:

1. Annealing test (for copper)
2. Tensile test (for Aluminium )
3. Wrapping test (for Aluminium )
4. Conductor resistance test
5. Test for thickness of insulation and sheath and overall diameter
6. Tensile strength and Elongation at break of insulation and heath
7. Hot set test for insulation and sheath
8. High voltage test
9. Insulation resistance test

 Routine test: The following shall constitute the routine test.

1. Conductor resistance test
2. High voltage test
3. Insulation resistance test
High Voltage Test (Water Immersion Test) :

Approximate 3 meters long core is removed as sample from the finished cable or
cord. The sample then is so immersed in a water bath at room temperature that its
ends protrude at least 200 mm above the water level. After 24 hours, an alternating
voltage of required level is applied between conductor and water. This voltage is
raised as per requirement within 10 sec and hold constant at this value for 5 min. If
the sample fails in this test, one more sample can be subjected to this test.

Test on completed cables (Acceptance and routine test) :

This test shall be carried out between conductors or between conductor and screen
/ armor. The test shall be carried out on required voltage the test shall be carried
out at room temperature and the time of application shall be 5 min no failure of
Insulation shall be occur.

Flammability Test :

Period of burning after removal of the flame shall not exceed 60 sec and the
unaffected portion from the lower edge of the top clamp shall be at least 50 mm.