How an electrical cable is made?

TOP CABLE
Welcome to TOP CABLE. We are one of the worlds largest manufacturers of electrical cables.

VIDEOBLOG
In this video blog we will show you 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 which require highly qualified staff.

1. CONDUCTOR 1.1. WIRE DRAWING 1.2. WIRING 2. INSULATION 3. PHASE WIRING 4. ADDITIONAL COVERINGS 5. OUTER SHEATH 6. QUALITY CONTROL 7. SHIPPING 8. SUSTAINABILITY

1. CONDUCTOR 1.1. WIRE DRAWING

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.

The copper arrives from the foundry to Top Cables factories in large coils weighing 5 tonnes. 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.

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.

1.2. WIRING
After the wire-drawing, the copper wires are grouped together to make conductors. This process is called wiring.

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.

2. 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.

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 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. 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.

ELECTRICAL INTEGRITY CONTROL

The whole length of the cable undergoes a voltage test to ensure the insulation layer does not have any faults.

3. PHASE WIRING
Phase wiring is the grouping of different insulated conductors to make a multicore cable.

The phases can be identified by colour or by numbering them.

ELECTRICAL INTEGRITY CONTROL

A voltage test is also carried out on the whole length of the manufactured cable during this process.

4. ADDITIONAL COVERINGS
And that is how an electrical cable is made. 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.

Mechanical 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.

5. 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 aggresion, 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.

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 products certification. There is also a meter by meter mark on the cable to help our customers with their stock control.

ELECTRICAL INTEGRITY CONTROL

A voltage test is also carried out on the whole length of the manufactured cable during this process.

6. QUALITY CONTROL
And that is how an electrical cable is manufactured. But the process does not finish here. At Top Cable we verify the quality of all our cables by carrying out rigorous checks before they are sold.

In order to guarantee the high quality required by Top Cables 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.

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.

7. SHIPPING
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 Cables logistics centres at all times, guaranteeing the availability of the product and allowing us to meet the tightest deadlines.

8. SUSTAINABILITY
We have created recycling systems at all Top Cables 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 specialised companies to be correctly disposed of.

This is how we guarantee that the environmental impact of our industrial activity is kept to a minimum.

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You can download this PDF http://www.topcable.com/en/virtual-tour You can view this video in http://youtu.be/uwFvGZcjQME

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