A look at Top 4 Configuration of Stranded Copper Wires

Let us take a look at the differ configuration of stranded cooper wires.

1. True Concentric

These wires have a central copper wire. This core is surrounded by a successive layers of alternately arranged strands with the length of each layer slightly larger than the successive layer. The lay direction is established by the twisting of the machine during the stranding process.
The lay length in these wires keep reducing as the layers are added to the inner strands.

2. Equilay

Also called as equally laid concentric cables, these stranded types of copper wires have helically arranged strands. The lay length is consistent unlike that in the true concentric strands. Rest of the features are same as that of its true sibling.

3. Unidirectional 

This is a special case of concentric stranding where the helically laid strands are laid in the same direction with increasing lay length. These configurations allows the conductor cable to be laid in a tight geometry with lowest tolerance for diameter variations throughout the length of the wire.
The wires are preferred for motors and transformers featuring in the high torsional simulations, like in automated production lines or in robotics. In short, it is easy to classify unidirectional stranded wire cables as “Robotics Cables”.

4. Rope

Rope stranding is also a type of stranded wire configuration where the strands of copper wires are arranged in a circular manner mostly comprising of 7 or 19 members. It is witnessed that the Rope stranding has the highest twisting and bending flexibility compared to other stranding mechanisms. The advantage of using Rope stranding is that the manufacturer can add successive layers of strands without compromising on the diameter tolerances, already fixed for the appliance.

Identification of Stranded Cables

Stranded cables are extensively used as Power cables and Submersible winding wires. Depending on the laying of the wires, they are classified into three families.

• Class B Power Cables
• Class C with higher flexibility quotient than Class B stranding
• Class D with highest flexibility, accommodating additional layers of stranding within diameter tolerance limits

Another classification of the stranded copper cables is done on the basis of rope layout and the kind of application it is employed in.

• Class G covering the Portable winding wires
• Class H Enamelled copper wires with polyesterimide insulation for better flexibility
• Class I cables for motor leads
• Class K stationary cables for cord and winding of No. 30 AWG wires
• Class M No.34 AWG Constant service

There are other braided varieties of the copper wires that more or less add extra level of robustness into the configuration. They are:

• Loaded twisted pair with extra inductance, used in load coils
• Bonded pairs
• Ribbon cables for connectors and printed circuit boards

Litz Wires

Extensively used in electronic circuits, Litz wires are insulated strands of thin copper wires woven or twisted around each other to reduce the Skin Effect and Proximity Effect.

They are used in transformers and inductors operating at high frequencies.

3 ways how use of Copper Wires have changed over a Period of Time

Copper is one of the noble metals that stay resistant to the effects of oxidation, corrosion and atmospheric moisture. Very few metals are as compatible as copper in the manufacturing of the wires and plates. For electrical purposes and conductor manufacturing, copper wires play a major role. Owing to excellent electrical conductivity and resistance to wear and tear makes bare copper wires the first choice in the application of standard metals in the electrical circuits. The use of copper wires is just a few hundred years old. During the 19^th century, scientists and engineers discovered the potential of copper wires as an electromagnetic material that can be alloyed as well.

Copper was majorly used as an ornament or as utensils. The improvement in machining processes harmonized with the metallurgical improvement ensured that copper climbed ladders of sophisticated electrical applications in short span of time.

 

We tell you 3 things that scientist discovered about copper wires in two hundred years that makes it an amazing element.

1 Initial use in transmitting electromagnetic waves

Copper wires have better of both worlds. It is an excellent electrical conductor as well as magnetic field conductor. It means it can be used as wire in transmitting signals. Morse code and telegraph are the best examples of stranded copper wires being used in the modern day world; finding is origin in the 19^th century. The diversification of the braided copper wires being used in marine navigation and radio signalling also is the part of application of electromagnetic waves.

2 Advent of electricity

Electricity is one of the greatest discoveries that changed the course of human evolution. From industrial era to the modern computer era, electricity has played a pivotal role. Copper wires, especially the bare ones have played a key part in transmitting electrical signals to remote parts of the world. Carrying the electricity from the powerhouse, where electricity is produced to homes and industries, is indeed possible because of the overhead transmitting lines made of braided and bare copper wires. They have stood against test of time by resisting the harsh weather conditions. They hardly slacken over a period of time and retain their physical properties effectively.

 

3 Copper wires alloyed with other metals

Stranded and braided copper wires don’t get hot even during continuous signal processing. It has a commendable resistance against wear and tear which leads to loss of metal. It has impressive corrosion resistance that makes it great for use even in bare forms. That’s exactly the reason why bare copper wires are so popular in the open-field signal stations. Copper can withstand temperature variations between -80 degrees centigrade to over 110 degrees centigrade without showing much of a variance in its physical and electrical properties. It is alloyed with tin, nickel and other noble metals for glaze and extra insulation. Even in alloyed form, copper wires are very flexible and can be used in much smaller appliances with easy installation and replacement possibilities.