Electrical Power Cable: Components and Ratings

Do you know who developed the first power supply system? Let the answer light up like a bulb in your mind. Yes, it was Thomas Edison! He did it in New York City in 1882. He used copper rods, which were covered in jute and positioned in rigid pipes containing a bituminous compound.

Well, the journey of an electrical power cable from then till now has been interesting with lots of changes, to be precise, improvements.

 Modern power supply

Modern cables for power supply are available in various types, materials, and sizes. Each one is designed based on the usage. Sometimes, big single insulated conductors are also known as cables in the electrical industry.

 Components of electrical power cables

There are 3 chief components:

• Conductors
• Insulation material
• Protective layering

The design of each cable varies depending on its application.

How a cable is designed and what material is used depends on:

• Current carrying capacity of the cable – It determines the conductor’s cross-sectional size.
• Working voltage – It determines insulation thickness.
• Environmental conditions – They include temperature, mechanical force on cable, exposure to chemicals and sunlight, and exposure to water. They determine type and composition of outer protective layering.

 Short circuit rating

Usually, size of conductor required for power supply inside cable is determined more by its capacity to transfer short circuit current than by its capacity to transfer sustained current. This is because during a short circuit a sudden gush of electric current passes for a few cycles. This is followed by a steadier current flow. The period ranges generally between 0.1 to 0.3 seconds. This is where the importance of material used to create electrical power cable comes to play. The material should withstand the sudden gush of current with minimum or nil damages or hazard.

 Current carrying capacity and voltage drop

The capacity to carry current answers the question as to what size of conductor should be. It is the highest permissible rise in temperature that dictates the safe current carrying capacity of a cable, especially an underground one.

Voltage drop determines design of conductor for a power cable. Manufacturers consider the maximum permissible drop in voltage from source to load to design a cable conductor.

Here, Ohm’s law comes to play that states that current passing between two points in a conductor is directly proportional to voltage present across both points.

Choice of material is important here. Undoubtedly, copper is the best choice to manufacture electrical power cable. Copper wire is an efficient conductor and features lower voltage drop for a particular size and length than aluminum wire. Again, larger sizes of wire show lesser voltage drop than smaller sizes with the same length.

While choosing a cable you must know power requirements, application, voltage conditions, and such things. These will determine what type of cable will suit your electric power needs. Reputable manufacturers like Rajasthan Electric provide excellent wires and cables that are tested to the core and produced keeping in mind quality standards. You can also get braided connectors, tin coated copper wires, enameled copper strips, nickel copper wires, and more from them.

Benefits of Using Braided Flexible Connectors

Braided flexible connectors are used primarily for the purpose of passing currents through unstable conducting equipment. This is because the conductivity and location of many devices keeps changing as a result of conditions like thermal expansion or vibrations or simple operational movements. This is why braided flexible connectors made from copper are found to be very useful.

These braids of copper wires are made for establishing connections between very big components. The smaller wires which make up the copper braids are seen to be resistant to breakage even under repeated movements and vibrations unlike larger wires. These braids are made from braided strands of metals which are placed around the central cable. When you place orders for the braided connectors, the manufacturers will design them depending on your specifications.

Why are braided flexible copper connectors useful?

The braided flexible connectors are very important parts of the electronics industries. These are prepared using copper and stainless steel. This is usually done to offer additional support and strength. The main purpose of such wires is to give maximum power outputs.

So, for those sectors where demands for power are higher and wires are likely to undergo a lot of load, the braided flexible connectors are preferred. They are cost-effective solutions which guarantee maximum output of power. They can successfully control the vibrations and absorb these. They handle the compression and expansion of wires when power is being transmitted through these. They can be custom designed to regulate machine-delivered vibrations. So, you will see that these connectors find a lot of use in electrolytic processors, transformers, computers, and power generators.

The communication and planting industry also makes use of such connectors. To choose manufacturers of these connectors, it is best to read online reviews about the products first and compare prices of the products quoted by multiple vendors.

 

 

Submersible Winding Wire – Uses, Features, & GST

Submersible winding wire is used in wide array of industries especially in submersible pumps. Highly pure electrolyte grade copper is used in manufacturing these wires. There are many renowned manufacturers of these wires that maintain high standards for creating extra softness in annealed conductors.

These submersible winding wires play extremely important role in proper functioning of heavy motors, where slightest quality issue or any kind of defect can lead to creation of big issues in the entire set-up. If there are any issue in the submersible winding wire then that may also lead to failure of pump during extremely important operations. That is the reasons why the leading manufacturers of such wires take into account all the possible failure issues so that at the time of manufacturing all the probable issues can be avoided.

In fact, numerous tests are conducted on the wire so that these wires have flawless quality. Some of the tests performed on these wires before releasing them in the market include elongation test, spring back test, melting point test, spark test, thermal ageing in air test, heat shock test, and many more.

Features

Submersible winding wire comes with numerous features and properties that make this the preferred choice of submersible pumps. Some of the features are listed and discussed below –

• Most important properties of these wires include chemical, thermal, mechanical, and electrical properties, which ultimately help in withstanding abrasions and frictional losses. Biaxially oriented synthetic film is used in production of insulating material. This material is then placed concentrically around the conductor. This has been seen to have a very high life.

• Tensile strength of these submersible winding wires is extremely high, which again supports at every point of the wire where excessive stretching takes place.

• Overall diameter of these wires is less than that of the conventional PVC winding wires. This makes the former easier to wind. That’s why submersible winding wire is preferred and so predominantly used in motors.

• With easier winding facility of the wire, the motor size of the pump also gets reduced. In fact, this facility helps in development of smaller pumps, which ultimately saves the costs of materials, stamping, and castings. It has been seen that these facilities save up to 25 per cent in cost of pumps.

• There are many other properties and features associated with the submersible winding wires. Some of them are dielectric strength, ability to withstand 130°c temperature for a short period of time or -60°C to 105°C continuously, less leakage of current, tear resistant, and more mechanical strength.

How GST Affects Submersible Winding Wire?

After the first government’s announcement of the GST rates, the lighting industry was apprehensive. Though there were revision of rates on June 3 and June 11, confusion persisted due to the presence of multiple lists as well as categorisations. However, the confusion was done away with in the 14th Goods and Services Tax (GST) Council Meeting, where it was clearly mentioned that the winding wires, LED lights/fixtures, Metal Core Printed Circuit Board panels, LED driver, and many more come in the 18 per cent rate bracket, much lower than the earlier proposed 28 per cent rate. After this announcement, it has been decided that no price increase will take place in the GST regime.

Braided Connectors – Utility And More

Braids manufactured suing many wires are, at times, used for flexible electrical connections between various large components. Braids score over large single wires in such cases since the many small wires in them are more resistant to breaking or chafing under constant pressure, like repeated motion or vibrations.

Braided connectors are manufactured using copper or stainless steel bellows. They are sometimes covered to offer enhanced support and strength. These are vital components of the electronics industry.

Connectors are used to join electrical circuits that are used as interface. It is the delicacy of the operationalnature of these connectors that force the manufacturer to be very careful when it comes to using precise calculations and configurations.

The most common metal used to make these connectors is copper. This is because copper has excellent thermal and electrical conductivity, a feature that makes it the perfect choice for making these connectors.

What these connectors do

The main purpose of braided connectors made by the leading providers in the industry, such as Rajasthan Electric Industries, is to deliver maximum output. These connectors have to do so even during times of peak performance.

The demand for power in the electrical sector is considerable and wires experience robust loads. Braided connectors are the most efficient solution to ensure optimal power output in such cases.

Here are some benefits of using these connectors:

•  They absorb and control the vibrations.

•  They provide minimal resistance to ensure seamless productivity.

•  During the transmission of power, they manage and control the natural expansion and compression of the electrical wires.

Some applications of these connectors are in the energy industry for generators, circuit breakers, transformers, wind turbines, etc. They are also used in other sectors such as military, aerospace, information technology, and more.

Low down on Copper Flexible Connectors and its types

Copper Flexible Connectors are used to transmit current across conducting mediums. These can be subjected to different motions, such as vibration, thermal expansion, or operational movement. These connectors have excellent flexibility, and provide maximum conductivity with minimum volt drop. While they are usually supplied in a non-insulation design, but if the customer so wants, they can be supplied with insulation sleeves of PVC, silicone, fiberglass, heat shrink, etc.

Laminated connectors

Some manufacturers also make laminated Copper Flexible Connectors. These are made by stacking multiple foils of electrolytic copper which is then pressed while high current is applied to it. A very special type of metal diffusion takes place. The metal melts and forms harmonized bonds. This gives an extremely negligible drop across the connector which helps increase its current carrying capacity and reduces its temperature rise.

No other metal is utilized in the process as the filler material to join the two layers together. There is a constant cross-section across the entire length of the connector. Also, it is possible to saw, drill, meld, and mill the contact areas of the connector without facing any issues.

These are built to customer specifications. They are used when an electrical connection has to be made in extreme conditions or environments, such as space constraints, low movements, low mechanism vibrations, etc.

These connectors are utilized as flexible expansion joints to connect bus-bars in industries such as power plants, switchgear units, etc. Most manufacturers offer these connectors in specifications set by the client and can completely customize the product according to their needs.

Braided connectors

Flexible braided connectors are manufactured using copper wire of any diameter as is specified by the client. They can be made by using bare, tinned, or silver-plated copper. The contact areas are pressed with bare copper connectors. These can be plated with tin or silver if the client so requires. For perfect conductivity, the ends can be dipped in hot tin.

These are for low and medium voltage applications only. They are used in the electrical industry in generators, wind turbines, rectifiers, substations, transformers, etc. These are used in conditions such as space paucity, heavy mechanical vibrations, thermal contraction/expansion of attached units, etc.

The Best Uses Of Copper Wire

Copper and its alloys are used in a huge variety of ways, right from common household wiring to marine vehicles. This is because copper has several excellent properties that make it so valuable in many industries.

Some of these are:

•    Malleability

•    Resistance to corrosion

•    Conductor of electricity

•    Ductility

•    Solderability

Many forms of copper such as solid or stranded bare copper wire, copper wire cables, and plated copper wire are manufactured by leading manufacturers, such as Rajasthan Electric Industries, today and are used in a staggering variety of industries, such as electrical, transport, construction, and more. The best part is that not all uses of copper are for conducting electricity and thus it is quite a useful and valuable metal.

The best uses of copper in wire form

These are:

Running electrical currents in buildings – right from small fixtures to major appliances, copper wires are used to carry electricity. They are considered the best since they are corrosion resistant and extremely durable. Finely twisted copper wires are utilized in ADSL and HDSL wiring for LANs.

Making jewelry pieces – this metal is a favorite of jewelry makers. They love its color and flexibility. It doesn’t corrode and makes the jewelry last longer.
For Deep-water fishing – it is used as the fishing line on the back of its ability to sink and its strength.

In land and marine vehicles – copper has heat and water resistant properties, which make it the ideal choice in the automotive industry.

In printers and fax machines – copper wire cables are used as F-connectors in TVs. Also, they are used to connect computers to printers and fax machines.

These are just a few good uses of copper wire. This metal is a hot property indeed and copper wire prices are considered as the indicator of economic health in the investment community.

What Makes Copper Foil So Valuable?

Among non-ferrous metals, copper is considered by many as an extremely versatile metal. It holds strong appeal in a huge range of varied industrial applications. Copper has been in great demand in the recent years, especially in the field of electronic products, such as IT devices, digital cameras, mobile phones, etc.

How Copper Foil is fabricated

There are two methods in which copper is converted into copper foil. These are:

•  Rolling

•  Electrodeposition

Rolling can be done using three different kinds of equipment – hot rolling mills, foil mills, and cold rolling mills. In electrodeposition, some treatments are also done that slow down the oxidation of copper.

At home

Copper is used rather rarely in household products. This is because aluminium foil has replaced it due to features such as better flexibility and resistance to heat. However, copper foil still persists in many applications in both the home and the industries since it has many features that aluminium cannot match.

Copper foil is also used in electrical appliances. Most of the foil offered in the market is made according to the set international standards where the content of copper is 99.99%. One side of this foil is treated with an electrodeposited finish that has an ensured enhanced high temperature elongation property. The foil’s micro structure is thermally stable and it has a high resistance to oxidation.

Most copper foils have the general composition of 0.1 mm thickness, up to 360 mm minimum width, and weight is per feet in kilograms.

Some other areas where this foil is used are transformer connectors, bus bars, control panels, and in equipment used for power transmission. It is also used for earthing protection in LT and HT electric panels.

Used in stained glass art

It is in the stained glass industry that copper foil has a major role. Here it is used to join two pieces of colored glass together. How this works is colored glass pieces are cut and placed into a design that is to be glued together later. Now, adhesive copper tape is wrapped around the edges of the glass pieces and these are soldered to strongly bond these pieces. All these pieces are thus joined to create a stained glass work of art that lasts for years.

Due to being light in weight and for its excellent glass bonding property, not only is it used for creating beautiful stained glass artwork, it is also used for repairing windows and making new ones. Soldered copper forms an almost indestructible bond that helps windows to last for a long time.

Sometimes, copper foil is also utilized in preserving and protecting certain household products and chemicals around the house. However, as mentioned before, the use of copper has lessened since aluminium is more in use nowadays, especially in households.

Opt For High Quality Submersible Winding Wire

Submersible Winding Wire is the most preferred choice of leading organisations of their inherent qualities.

Select high quality Submersible Winding Wire

The primary focus should be simply given on the quality of the Submersible Winding Wire. They should have substantial chemical properties besides excellent thermal properties. Since these wires are used for electrical conditions and wires of poor quality will prove to be hazardous. The life and smooth functioning of the machines, pumps and electrical appliances depend on the quality of the wire. Cheaply priced wires undoubtedly may save you some money, but in the longer run they give lot of functional hassles
Choose a reputed Manufacturer for buying Submersible Winding Wire

Submersible Winding Wires have high tensile strength and should be very stretchable so that they can handle frictional losses. These wires have a strong shielding, which is made by using high quality synthetic film. The winding of these wires are different than normal PVC wires .It is imperative to select a trusted Submersible Winding Wire that manufactures superb quality wires. There are numerous manufactures in the market but it is best to choose a manufacturing company whose product has been used over considerable period of time. Moreover, it has been proven that it is extremely superior in terms of quality. The winding wires manufacturers should have a good reputation in manufacturing Submersible Winding Wire in the industrial market.

 Purchase online from a reliable Submersible Winding Wire Manufacturer

In this era of ecommerce leading manufacturers have their portals where you can review the product. However, ensure that the company has a dependable online identity in the domestic and international marketplace. Browse and read the reviews of previous clients in order to select a reputed front-ranking Submersible Winding Wire manufacturer who can provide high quality and cost effective products using innovating technology. Compare the prices online and get best bargains in order to gain the competitive edge.

Copper Flexible Connectors – Everything You Wanted to Know!

There are two most common queries regarding copper flexible connectors. While the first is the knowledge regarding them and the second is the way of buying it. In this article these two aspects will be dealt with closely. While

Copper flexible connectors are basically made up of copper metals that can assume any type including tinned copper, silver coated copper, or simply bare copper. The copper connector manufacturers are capable of manufacturing these products in accordance with the specific needs of the customers. It can be seen that there is a huge demand of these kind of connectors in the electric industry. They are found to be quite useful when used in high quality connectors. For improving connectivity, a typical process is used. Per this process, copper connectors are cold pressed for proper manufacturing. In order to connectivity improvement, hot tin is used. The ends of copper connector are dipped in hot tin. When manufacturing these connectors, two kinds of wires are used. While one is round copper stranded wires, the other is flat copper braided wires.

When the copper wire is manufactured, a special process is followed in the entire process. This process ensures that they can be used instantly and are ready for use. There are two important properties of copper. They are:

• High electrical energy

• Heat conductivity

These two properties make them ideal to make copper connectors. In fact, an alloy of steel or aluminium is used so that these connectors become more durable as well as stronger. Optimum power output is achievable and that’s too with the help of copper flexible connectors. If a business needs copper flexible connectors, what that business is required to do is provide manufacturer with the necessary details. Different types of specifications are available in these connectors and therefore the buyer has to ask for the special aspects that are need by his or her business.

It is always desirable that a business buys copper flexible connectors from established as well as reputed manufacturers only. This is because of the simple fact that they ensure exact quality standard as claimed. One of the greatest advantages of getting only the high quality products is that they have following two properties:

• High resistance

• Easy installation features

In fact, there is a huge demand for these copper connectors in the market and this is because of the simple fact that they provide consistent performance. It has been seen that they are more and more used in two industries and they are automobile industry as well electrical distribution industry. In fact, another area where copper flexible connectors are used is in switchgears.

At electrical distribution systems these copper flexible connectors are used because of the simple fact that high conductivity features. They can also be manufactured in non-insulation style and can be used with PVC or Silicon insulation sleeves. These are some of the reasons why more and more businesses are weighing in favour of increased use of these connectors.

Nickel Copper Alloy for Electrical Wires? – Is it Good or Bad

Copper is extensively used for the manufacture of electrical wired because of its high electrical conductivity and low resistance. Copper wires are also popular because of the tensile strength and the ductility of the metal. Copper is relatively cost effective and the price points largely depend on the quality of material used.

Copper wires are standardized and accreditation need to be checked well before sourcing it. Ideally, they should be procured from established and reputed manufacturers who are quality conscious and known for providing high quality wires for safety and reliability. Alongside copper wires, variations in the form of alloys are also available. One of them is cupranickel which is a nickel copper alloy.

How is Nickel Copper Alloy Different?

When nickel is added to copper, it brings along some of its own properties and creates a new set of properties for the alloy. Some of the distinctive features of this allow include:

1. More tensile Strength: When nickel is added to copper, the tensile strength of the metal changes and is enhanced. Nickel increases the tensile strength and therefore, in terms of manufacturing ease, the nickel copper alloy is a better choice as compared to pure copper, for drawing wires.
 
2. Higher Proof Strength: Wires made from a mix of copper and nickel has more proof strength as compared to those manufactured by copper alone. Therefore wires manufactured from nickel copper alloys are likely to be more strong and durable and hence would last longer. So, if you wish to opt for wires that are likely to last longer, then the alloy made ones will be better suited for sure.

3. Better Corrosion Resistance: Wired manufactured from nickel copper alloys will be better suited for environments that are exposed to extensive corrosion. For instance if the wires are meant for humid conditions or marine usage, it is always more advisable to stick to cupranickel instead of copper alone. Better corrosion resistance means less frequent replacements required and saving on capital costs.

4. Lower Electrical Conductivity: Although the alloy appears to be a superior choice to copper in many ways, it does not match up to the electrical conductivity of copper. So, if you are looking for highly effective wires, copper is perhaps still the best choice as compared to nickel copper alloy.

Choice Depends on Nature of Usage

Choice of wires depends on the nature of usage. If you are looking for high speed performance, copper is perhaps better. However, if longevity is your preference, the alloy could suit your purpose better.

Once you have determined on your choice of make, it is important to understand that the advantages can only be realized when you have sourced your wires from a trusted source. Make sure you choose from a company that sticks to standardizations. It is also important to know whether the company you are sourcing from sticks to the right norms for manufacturing and adheres to all directives.

Visiting the manufacturing facility and checking out the proceedings there will ensure complete peace of mind, especially if it happens to be a bulk purchase.