How Are Electrical Wires Manufactured? Miracle Electronics

1
How Are Electrical Wires Manufactured - Miracle
Electronics
We can see all sorts of electrical wires around
us today some being visible like those that are
used to connect different equipment and
appliances to the power grid, and others that are
not seen like underground utility wires. With
all of these combined, there are innumerous kinds
of wires of various types and diameters
available today. And, all of these wires are
manufactured through a long and complex process,
and with great care, in order to provide years of
reliable and fault-free service. Let us get into
the details of wire manufacturing to explain to
you the entire process thoroughly. But, before
getting into the process, let us first understand
what comprises a wire. A simple wire is built
with an electrical conductor, made of copper or
aluminum, which permits the flow of electricity,
and also allows for insulation that ensures
current flow without any leakage.
Wire drawing This is the first stage of the wire
manufacturing process, wherein the diameter of a
wire is gradually reduced to the pre-set value.
2
Annealing This is the process of heat
treating the wire, which is basically done to
improve the wires physical properties like
conductivity and ductility. Wiring During this
stage, multiple wires are combined to create
conductors of varying cross-sections. Hot
extrusion This is the process where the conductor
is covered with insulating material, wherein the
choice of this material depends upon the
requirements needed by the wire. Also, the
quality of insulation depends upon the capacity
and thermal resistance. Higher capacity and
insulation thickness mean higher maximum surface
voltage of the wire. It can also be said that
higher thermal resistance means that the
conductor can transmit more electrical
power. Voltage testing This is the test applied
to the entire length of the wire to ensure that
the insulation is free from faults and has no
current leakage. Phase wiring This is an
additional stage in the case of multi-core wires
manufacturing, where several conductors are
combined. And, the different phases are marked
with different colors, numbers, or any other
sort of marking to distinguish them from one
another. When using multiple wires, it is better
to use them in the form of a wire harness so as
to keep the wires neatly organized in a lesser
space, and protected against all sorts of
vibration, abrasion, and moisture. If you are
looking for one such equipment, Miracle
Electronics is the wire harness manufacturer in
India you must approach to get A-grade wire
harnesses that are certified and approved by
DGAQA and MSQAA for platform specific
applications. Additional protection Additional
layers are added to the wire to improve its
characteristics in case it has to withstand high
electrical stress or highly demanding operating
conditions. Moreover, the wires signal is
insulated with screens to protect it from any
harsh outside influences. For further protection
3
against mechanical or any other type of damage,
steel or aluminum protection is applied to the
wire in the form of braids, wire, or strips. The
purpose of the outer sheath of a wire is to keep
away elements like moisture, and to prevent the
wire from mechanical impact. This is why the kind
of additional protection mentioned above is not
mandatory. In fact, if special circumstances are
not to be encountered, the outer sheath can be
the final layer of the wire, which can be made of
various kinds of polymers as per the required
protection level. For more details, please
visit Miracle Electronics