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CO1 LO1Learning Content # 5
Wire
Forms of wire
Solid wire
Solid wire, also called solid-core or single-strand wire, consists of one
piece of metal wire. Solid wire is useful for wiring breadboards. Solid
wire is cheaper to manufacture than stranded wire and is used where
there is little need for flexibility in the wire. Solid wire also provides
mechanical ruggedness; and, because it has relatively less surface area
which is exposed to attack by corrosives, protection against the
environment.
Stranded wire
Stranded copper wire
Stranded wire is composed of a number of small wires bundled or
wrapped together to form a larger conductor. Stranded wire is more
flexible than solid wire of the same total cross-sectional area. Stranded
wire is used when higher resistance to metal fatigue is required. Such
situations include connections between circuit boards in multi-
printed-circuit-board devices, where the rigidity of solid wire would
produce too much stress as a result of movement during assembly or
servicing; A.C. line cords for appliances; musical instrument cables;
computer mouse cables; welding electrode cables; control cables
connecting moving machine parts; mining machine cables; trailing
machine cables; and numerous others.
At high frequencies, current travels near the surface of the wire
because of the skin effect, resulting in increased power loss in the wire.
Stranded wire might seem to reduce this effect, since the total surface
area of the strands is greater than the surface area of the equivalent
solid wire, but ordinary stranded wire does not reduce the skin effect
because all the strands are short-circuited together and behave as a
single conductor. A stranded wire will have higher resistance than a
solid wire of the same diameter because the cross-section of the
stranded wire is not all copper; there are unavoidable gaps between
the strands (this is the circle packing problem for circles within a
circle). A stranded wire with the same cross-section of conductor as a
solid wire is said to have the same equivalent gauge and is always a
larger diameter.
However, for many high-frequency applications, proximity effect is
more severe than skin effect, and in some limited cases, simple
stranded wire can reduce proximity effect. For better performance at
high frequencies, litz wire, which has the individual strands insulated
and twisted in special patterns, may be used.
Number of strands[edit]
The more individual wire strands in a wire bundle, the more flexible,
kink-resistant, break-resistant, and stronger the wire becomes.
However, more strands increases manufacturing complexity and cost.
For geometrical reasons, the lowest number of strands usually seen is
7: one in the middle, with 6 surrounding it in close contact. The next
level up is 19, which is another layer of 12 strands on top of the 7.
After that the number varies, but 37 and 49 are common, then in the
70 to 100 range (the number is no longer exact). Even larger numbers
than that are typically found only in very large cables.
For application where the wire moves, 19 is the lowest that should be
used (7 should only be used in applications where the wire is placed
and then does not move), and 49 is much better. For applications with
constant repeated movement, such as assembly robots
and headphone wires, 70 to 100 is mandatory.
For applications that need even more flexibility, even more strands are
used (welding cables are the usual example, but also any application
that needs to move wire in tight areas). One example is a 2/0 wire
made from 5,292 strands of No. 36 gauge wire. The strands are
organized by first creating a bundle of 7 strands. Then 7 of these
bundles are put together into super bundles. Finally 108 super
bundles are used to make the final cable. Each group of wires is
wound in a helix so that when the wire is flexed, the part of a bundle
that is stretched moves around the helix to a part that is compressed
to allow the wire to have less stress.
Prefused[edit]
Varieties[edit]
The following are the Common Electrical Wire Splices and Joints
Y-Splice
Knotted tap
Joint all the splices discussed up to this point are known as butted
splices. Each was made by joining the free ends of the conductors
together. Sometimes, however, it is necessary to join a branch
conductor to a continuous wire called the main wire. Such a junction
is called a tap joint.
This is used where the tap wire is under considerable tensile stress
circuit.
Aerial Tap
Cross Joint
The same application is done as in plain tap and the only difference is
that this tap is a combination of two plain taps place side by side with
each other.
Coaxial cable
Twisted pair cabling
Any current-carrying conductor, including a cable, radiates
an electromagnetic field. Likewise, any conductor or cable will pick up
energy from any existing electromagnetic field around it. These effects
are often undesirable, in the first case amounting to unwanted
transmission of energy which may adversely affect nearby equipment
or other parts of the same piece of equipment; and in the second case,
unwanted pickup of noise which may mask the desired signal being
carried by the cable, or, if the cable is carrying power supply or control
voltages, pollute them to such an extent as to cause equipment
malfunction.
The first solution to these problems is to keep cable lengths in
buildings short since pick up and transmission are essentially
proportional to the length of the cable. The second solution is to route
cables away from trouble. Beyond this, there are particular cable
designs that minimize electromagnetic pickup and transmission. Three
of the principal design techniques are shielding, coaxial geometry,
and twisted-pair geometry.
Shielding makes use of the electrical principle of the Faraday cage. The
cable is encased for its entire length in foil or wire mesh. All wires
running inside this shielding layer will be to a large extent decoupled
from external electrical fields, particularly if the shield is connected to
a point of constant voltage, such as earth or ground. Simple shielding
of this type is not greatly effective against low-
frequency magnetic fields, however - such as magnetic "hum" from a
nearby power transformer. A grounded shield on cables operating at
2.5 kV or more gathers leakage current and capacitive current,
protecting people from electric shock and equalizing stress on the
cable insulation.
Coaxial design helps to further reduce low-frequency magnetic
transmission and pickup. In this design the foil or mesh shield has a
circular cross section and the inner conductor is exactly at its center.
This causes the voltages induced by a magnetic field between the
shield and the core conductor to consist of two nearly equal
magnitudes which cancel each other.
A twisted pair has two wires of a cable twisted around each other. This
can be demonstrated by putting one end of a pair of wires in a hand
drill and turning while maintaining moderate tension on the line.
Where the interfering signal has a wavelength that is long compared to
the pitch of the twisted pair, alternate lengths of wires develop
opposing voltages, tending to cancel the effect of the interference.
Fire protection
In building construction, electrical cable jacket material is a potential
source of fuel for fires. To limit the spread of fire along cable jacketing,
one may use cable coating materials or one may use cables with
jacketing that is inherently fire retardant. The plastic covering on some
metal clad cables may be stripped off at installation to reduce the fuel
source for fires. Inorganic coatings and boxes around cables safeguard
the adjacent areas from the fire threat associated with unprotected
cable jacketing. However, this fire protection also traps heat generated
from conductor losses, so the protection must be thin.
To provide fire protection to a cable, the insulation is treated with fire
retardant materials, or non-combustible mineral insulation is
used (see Mineral-insulated copper-clad cable).
Types
A 250 V, 16 A electrical cable on a reel.
Wiring Terminology
These larger wires in your home are carrying circuit voltage, and they
can be very dangerous to touch. There are also several wires in your
home that carry much lesser amounts of "low-voltage" current. These
are less dangerous, and with some, the voltage carried is so low that
there is virtually no chance of shock. However, until you know exactly
what kind of wires you are dealing with, it's best to treat them all as
dangerous.
NM Cable
Often called “Romex” after one popular brand name, NM cable is a type
of circuit wiring designed for interior use in dry locations. Most NM
cables have a flattened tubular shape and run invisibly through the
walls and floor cavities of your home. Almost all of the wiring in outlets
and light fixtures a modern home is NM cable. The most common sizes
and their amperage (amp) ratings are:
NM cable is now sold with a color-coded outer jacket to indicate its wire
gauge:
UF Cable
THHN/THWN Wire
THHN and THWN are codes for the two most common types of
insulated wire used inside the conduit. Unlike NM cable, in which two
or more individual insulated conductors are bundled inside a plastic
sheathing, THHN and THWN wires are single conductors, each with its
color-coded insulation. Instead of being protected by NM cable
sheathing, these wires are protected by tubular metal or plastic
conduit.
o T: Thermoplastic
o H: Heat-resistant; HH means highly heat-resistant
o W: Rated for wet locations
o N: Nylon-coated, for added protection
THHN and THWN wires have colored sheathings that are generally used
to identify their function in a circuit:
THHN and THWN wires are circuit wires that should never be handled
when the circuits are turned on.
Low-Voltage Wire
Coaxial Cable
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Barbed wire
Cable
Chicken wire
Electrical connector
Electrical wiring
Litz wire
Piano wire
Razor wire
THHN
Tinsel wire
Wire bonding
Wire gauge
Wire netting
Wire rope
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Wollaston wire
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Electrical cable
From Wikipedia, the free encyclopedia
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For other uses, see Cable (disambiguation).
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Contents
1Etymology
2Modern applications
o 2.1Cables and electromagnetic fields
o 2.2Fire protection
o 2.3Types
o 2.4Codes and colours
3Hybrid cables
4See also
5References
6Further reading
7External links
Etymology[edit]
This section does not cite any sources. Please
help improve this section by adding citations to
reliable sources. Unsourced material may be
challenged and removed.
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cable" – news · newspapers · books · scholar · JSTOR
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This section needs additional citations for verification. Please
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2018) (Learn how and when to remove this template message)
Further reading[edit]
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