Electric Wire

How its made?

 The world of electricity can be very
complicated.
Well, we know electrical wires are designed to
carry current from one element to another.
What we DONT know is how an electrical
wire is even made.
So, lets take a tour
 The process of manufacturing
Electric Wire
Conductor
Insulation
Screen if required
Assembly
Inner coverings
Armoring
Outer sheath
Quality control
Shipping
Sunstainability
 Basic
components of
wire

Conductor Insulation

Channels Maintains flow

current of electricity in
through wire 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.
 Manufacturing Process
The first stage in the manufacturing process of a
conductor is the wire-drawing.
Reducing the diameter of the wire gradually to
fit its final diameter to increase ductility and
conductivity.
The wire is drawn further to decrease the
diameter of the wire to the size needed for
each kind of conductor
The second stage of this process is annealing
The wires undergo a heat treatment called
annealing.
Annealing is a process of heating metal and
allowing it to cool slowly in order to remove
internal stresses and toughen the metal.
The point of this treatment is to increase the
conductivity of the wire.
Annealing Furnace
 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 next process is insulation.
Placing an insulating cover over the conductor
to prevent current leakages.
The insulating material is added by a process
of extrusion at high temperature.
Several insulating materials may be used: PVC,
EPR, XLPE, etc.
contd..
 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 is the grouping of different
insulated conductors on assembly machines.
The phases can be identified by colour or by
numbering them, check HD standard HD 308
for colors and IEC 60502
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 made.
 Additional Elements
Screens:
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.
Armour:
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.
Outer-sheath:
Cables usually have an outer polymer covering
for protection called the "outer-sheath".
It protects the conductors and their insulation
from external elements which may change
their electrical properties, such as moisture.
Also protects them from mechanical
aggression, which may occur during the
installation of the cable.
 Quality Control
Wires undergo extensive quality control checks in
our laboratories, ensuring all the wires are free
from defects and are ready to be sold and this
according to each type and international
standrads 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 wires will work perfectly.
QC System
 Logistics
Orders are managed at different logistics
centres and then they are shipped out to the
customers.
Warehouse Management System (WMS)
provides with information about the stock
status at logistics centres at all times,
guaranteeing the availability of the product
and allowing to meet the tightest deadlines.
Thank you