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What should be kept in mind while making an Electrical Copper Wire!

Electrical copper wires play a pivotal role in guiding and shaping the industrial development of any state. Therefore, it becomes imperative for manufacturing units to keep in mind the quality and durability of these wires.

Electricity has become a synonym for the industrial and economic development of the country. The demand for a 24X7 power supply has increased the pressure on PSUs to generate and transmit power to all the households.

This could be surmised from a simple fact that India’s production of electricity was 1362 MW in the year 1947 which has boosted to 267 GW as per data collected in March 2015. The per capita electricity consumption has also gone up from a mere 16.3 KWh in the year of independence to 1010 KWh in the year 2015 according to a research paper published in the journal of Indian Electrical & Electronics Manufacturers’ Association (IEEMA).

The impetus for transforming all sectors of our economy, namely, Primary, Secondary, and Tertiary could be augmented by selecting a proper type of electrical copper wire. This could make our machines and engines more energy sufficient.

What is an electrical copper wire?

It is an assemblage of electric grade copper in a ductile form having a protective covering of an insulator which also binds these conductors. These cables are used to transmit current (I). The protective sheath is used to isolate the conductors from other things which might result in loss due to electric short circuits or other fatal accidents and loss of power.

Electrical power cables come in myriad sizes and varieties depending upon the use. Insulated copper wires or any other power cables could be divided into three parts as follows:-

Conductors drawn in wires
Insulation
Protective covering for external interventions

Following factors are taken into consideration in the making of copper wires:-

Voltage
Current carrying capacity
Thickness and quality of insulation
The cross-sectional size of the copper wire
Resistance
Temperature
Exposure to chemicals
Exposure to water or sunlight
Mechanical durability

Copper wires that are directly buried deep underground and exposed like wires used in transmitting current may have a metal armor in a form of a light but strong wire mesh that is wrapped around the wire to make it durable. The wire mesh is ideally made of steel or Aluminium. They are designed in such a way that despite the fact they are connected with earth wire, they don’t carry current in them.

Stranded copper and aluminum is widely used for making electrical wires. The cable may contain an extra insulated conductor for neutralizing the circuit and earth connections. Some electric wires that are used outdoors may be devoid of any protective covering or sheath. If the cable is made of stranded copper wires, they are necessarily enclosed in a sheath.

The materials used for protective sheaths are determined on the basis of their resistance to following things:-

Water
Underground pressure
Oil
Chemicals
Sunlight
High temperatures

There is a need to produce copper wires keeping these in mind because the growth of our economy depends on the proper functioning of power supplies.

Copper – Much More Than Just Bare Strips and Bunched Wires

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Ever saw mother offering sweet holy water to sun god from a reddish brown pot, or observed your grandmother admonishing about drinking water kept in a particular jar or heard of centuries old culture of throwing coins into holy rivers? In India, one must have come across the paraphernalia of the pundit and him recommending someone to wear a ring to please a certain god. Behold! Here comes the mighty Copper- the king of metals, the polymath. It is very adventurous to ascribe an adjective meant to glorify a human being. But, copper deserves without an ounce of doubt. It pleases gods, it could be adorned as a jewelry and above all it’s good for rivers and your health. What else do we need! Copper has been crowned as the first metal to be extracted and used for engineering purposes. Initially, it was used by Mesolithic man around 6000 B.C. for making basic tools, weapons and vessels.

Copper is a metal which is not highly reactive. It slowly reacts with oxygen to form a platina which stops corrosion further. It has high thermal and electrical conductivity which makes it an ideal material to use in the electrical field. These properties of copper are incorporated in myriad ways, two amongst them are, namely, bare copper strips and bunched copper wire. Bare copper strip could be used in defense, hydro power projects, ship building, electrical conductors etc. In industrial applications, it could be used in automatic machines which reduces the production costs. As a less reactive metal, it becomes most suitable for the terrains which have high salt content in their soil. Its replacement rate is also very low, making it feasible and reliable.

Copper wires, whether solid or bunched, are accommodated in a wide range of products. They are literally everywhere i.e. in your earphones, fans, coolers, juicers, circuit boards etc. you name them and the coppered genie is already there! And it’s not at all exaggeration but simple truth.

Bunched copper wires provide flexibility. Copper in bunched wire form is extensively exploited in areas of where motion is explicitly required. It is a metal filled with paradoxes as it is soft yet ductile and strong. This could be ascertained from the fact that earphones complete more than 365 days despite being subjected to the throes of purgatory!

Copper – A Highly Diverse Metal for Humanity

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Copper: Ubiquitous, Tremendously

There is no shortage of copper in our everyday life. As a matter of fact, there are very few spheres where copper – and, in particular, copper wire – does not play at least a small part in making things work.

Let us take, for example, the prevalence of electricity. Life as we know it would grind to a complete stop in a matter of minutes if the life line of electricity were to be cut off for some reason. Since the entire system of power provision runs on the infrastructure made of metals and plastics that are manufactured to be above certain standards. Copper wire falls under such strictly monitored infrastructure, since it would not be practical to let any quality of copper wire be relied upon to deliver power to homes, factories and workplaces.

Even the simplest electrical and electronic devices use one form of copper or another, and even where aluminum has replaced or supplanted copper, we can be sure that copper still holds its ground in the majority of sectors where it has traditionally been used.

There is, like said above, virtually no area of modern life that is untouched by copper, whether in wire form or not. Its ductility and malleability have long been considered excellent by any standards of human usage, right from making utensils and tools in the early days of human civilization to the most advanced supercomputers that are defeating human players at the game of Go.

Copper Wire: Thinned & Tinned!

Now, just because copper is a versatile, useful, workable (in terms mentioned earlier, i.e. malleable and ductile) and above all, conductive, this list of good characteristics does not automatically mean it can be used as it exists (or has been used earlier) in all situations. Certain specific applications require different characteristic of materials than just plain old copper.

Enter the advantage of pairing or mixing two or more metals into one alloy – and sometimes, just putting them together structurally, without any chemical interaction between the two (or three, or four, or more).

The most important quality that we can seek to impart to copper, as useful as it is, is to ensure it remains in prime shape throughout the life of the component it has been used. Tin is the material that can be used (and has been already) to make tinned copper wire, which makes the wire resistant to corrosion from humidity, which is quite a huge factor in tropical climates such as ours. As an added advantage, tinned copper wire also makes it easy to solder those tricky little components that make electronics tick.

Suffice to say, copper wire, and especially tinned copper wire, has enabled more than what could have been achieved using just plain old copper – not to demean copper in any way: it is an unimaginably useful metal for humans!

Fascinating Attributes of Power Cable and Fiber Optics

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When more than one stripped copper wires are to be used for conducting electrical current over a distance, we need to use a power cable for safe and effective transmission of electrical power. These cables are also known as electrical cables and vary in terms of sizes, applications, configuration and efficiency.

Any electrical cable is made by combining two or more copper or glass wire components and an insulating shield. Individual shielding of copper wires is essential if the cables are going to transmit high voltages. Common shielding of wires protects the entire cable from environmental hazards and also offers added insulation. These jackets are usually produced by using synthetic polymers.

Major types of electrical cables

Pairs of insulated copper wires are twisted around each other for producing twisted pair power cables. These are commonly used for wiring or cabling applications in telephone as well as Local Area Networks. Individual copper wires in these cables are color coded and the insulation enables prevention of cross-talk or external noise.

Coaxial power cable has a dielectric insulator that covers a copper plated core and the layer of insulator is shielded by a copper shield that is in a woven form. The entire configuration is enclosed inside a polymer sheath. These are designed for catering to multiple applications including television networks, and video or audio networking equipment.

Power cables in high voltage electrical transmission are shielded for prevention of interference of external power frequencies or radio signals. There can one or more insulated wires inside a shielding that is generally of woven braids or aluminum Mylar foils.

Flat twin or ribbon power cable is another form of electrical cable that consists of parallel insulated wires to facilitate concurrent transmission of multiple data and signals. Ribbon electric cables are extensively used for connecting network devices. One can also find these cables being used in computers for connecting core components of Central Processing Unit with motherboard.

Growing use of fiber optics

Fiber glass wire is the favorite choice of engineers for Information Technology related applications. These are popularly known as fiber optic wires or cables. Unlike copper power cable, fiber optic cables are capable of transmitting light and are immune to interferences of electromagnetic fields. Fiber optic cables are used for greater security as well as reliability in an environment that involves high voltages.

Transmission of digital information via fiber optic cables happens by conversion of digital signals into light pulses for transmission across the glass fibers. As soon as the light pulses reach their destination, these are converted back into digital signals.

Transmission of signals through fiber optics is significantly faster due the use of light pulses. It is possible to transmit signals of multiple wavelengths simultaneously since these do not interfere with each other.

Emergence of fiber optics has facilitated faster access of internet. It is also used in manufacturing of High Definition televisions to boost quality of picture and audio signals. Since these are capable of handling higher volumes of data, fiber optic cable can easily replace copper power cable.

What Are Key Benefits of Using Copper Electrical Wire?

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There are many good reasons to use copper electrical wire, particularly for safety purposes. You will find that most electrical and electronic goods and appliances use the copper electrical wire. This is why it is one of the most extensively used wires. Even though there are other varieties like fiber-optic cables, copper wires continue to be popular. There are some important advantages which you can enjoy when you use the copper electrical wire.
What Are Key Benefits of Using Copper Electrical Wire

Key benefits of the copper electrical wire:

To start with, copper wiring is known for its conductivity and heat resistance. They rank next to silver in terms of conductivity. Moreover, the copper wires are also capable of handling much heavier loads of electricity as compared to non-precious metals. Copper has higher resistance power to heat and therefore can successfully do away with overloading issues.

Copper electrical wire is also preferred because it is ductile and malleable. The wires are even thinner than human hair and they can be easily bent or twisted as required. This is why copper wiring is perfect for constricted areas where the wires may need to be bent. You will not have to worry about the wires breaking or getting damaged when they are being twisted. Copper wire finds use both in heavy equipments like making of thick cables for electrical posts or for appliances like headphones which need ultra-thin wires.

Copper finds use is a variety of industries like manufacturing, electrical and electronic, telecom companies and even marine industries. This is because copper wires have very high thermal and electrical conductivity. Unlike silver which is known for highest conductivity, copper is highly affordable. In industries like marine or construction where wires have to be very flexible, copper finds a lot of use.

Copper electrical wire is preferred because this metal has a very high melting point. This means that it can withstand high temperatures. They are safe and will not melt easily.

As a metal, copper is very strong and the wires made from copper are found to have high tensile strength. This makes the copper electrical wire very beneficial for the telecommunication industry wherein the wires are needed for sending signals across very long distances.

In terms of compatibility too, copper wiring is popular because it can work easily with other metals. You will find a variety of copper wires like the bare copper wire, stranded wire, tinned copper wire etc.

Copper electrical wire has high resistance to corrosion. This is especially important for the marine industry where equipments are exposed to a lot of moisture. Because of excess humidity in the air, metals tend to experience breakdowns frequently. Copper however is resistant to rusting and this makes it much desirable for under-water equipments and marine appliances.

Installing and working with the copper electrical wire is simple and hassle-free. It is a strong and durable metal which can be set up and bent to suit buyer requirements.

6 Key Benefits of Call center outsourcing for a manufacturing company

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Call center outsourcing industry has witnessed a huge growth in the last two decades. Companies outsource their non-core operations to reliable parties in order to focus on their core operations. Call center outsourcing helps companies optimize operations, enhance customer service and improve the bottom line.

If you run a manufacturing company, call center outsourcing can benefit you in several ways:

1) Improved customer service

Your customers and supply chain partners may have queries 24*7 but you may not be able to provide round-the-clock customer service. Call-Center-Services

Call center outsourcing allows you to have a team of competent professionals that cater to your customers at all times. This obviates the need for setting up a separate customer support department. Your customers can connect with this team through an array of communication channels and get their queries answered satisfactorily.

2) Reduced cost of operations

Outsourcing call center services is more cost-effective than managing them on your own. When you outsource services, you are done away with the need for hiring new employees, training them and buying new equipment. Whatever money you save here can be used in optimizing your manufacturing process and improving your product.

3) Professional expertise

When you outsource any process, you delegate it to a team of professionals who hold expertise in that process. They are aware of the latest tools, technologies and trends in that area. This assures you of the quality of the service delivered.

saves you from the need of hiring new employees and allocating several weeks in training them for the job.

4) Competitive edge

Call center outsourcing helps you focus on your core business operations. You can dedicate your time, energy and resources in improving your product and enhancing customer experience. This allows you to achieve an edge in today’s fiercely competitive business landscape.

5) Handling peak volume

If you manage call center operations on your own, you may not be able to handle peak volume overflow. This will increase customer complaints and lead to customer dissatisfaction. When you outsource such processes to a reliable partner, such challenges do not come up. Most of the outsourcing vendors are prepared to handle high volumes at any time of the day.

6) Access to valuable insights

When you outsource a call center process, you have access to customer data collated through different channels. This data can be analyzed to gain valuable insights regarding the customer and understand their needs and challenges. This helps you to serve your customer better and offer them personalized solutions.

The bottom line

Call center outsourcing offers several key benefits to manufacturing companies. You can hire a group of competent professionals to get your work done satisfactorily, and that too with the latest tools and technologies. You can delegate mundane, repetitive work to a reliable partner while focusing on your core operations. All these benefits help you stay ahead of the competition.

Bare copper strip: Why is it the preferred choice of electrical appliance manufacturers?

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Copper strips are products that find extensive industrial and domestic usage. Copper strips come in several forms. Some popular ones include: paper copper strip, braided copper strip, enameled copper strip, and bare copper strip.

Out of all these forms, bare copper strips are extensively used in electrical appliances and are the preferred choice of many electrical product manufacturers.

Let us discuss the properties of bare copper strips that make it popular among manufacturers:

Ductility and Malleability: One of the most striking features of bare copper strip is its ductility.

Bare copper wires can be easily pulled or twisted and, therefore, can be easily fitted in areas or corners that are hard to reach.

Besides, bare copper wires are malleable. They are soft and can be easily shaped and manipulated. They do not break easily under pressure. All these properties ensure a smooth installation of electrical wires.

High Electrical Conductivity: Copper has high electrical conductivity. In fact, the electrical conductivity of copper is the highest among all non-precious metals. This property makes bare copper strips the preferred material for many electrical appliances.

High Thermal Conductivity and High Melting Point: Copper is a good conductor of heat. It allows heat to pass through it easily and therefore bare copper strips are a great choice for electrical appliances that tend to generate a lot of heat.

Copper also has a high melting point. High melting point ensures the wires do not burn at very high temperatures and the electrical appliances remain secure. It means if you are using wires with copper strips, you don’t need to worry about electrical fluctuations or fire hazards.

Corrosion-resistance: Copper is resistant to corrosion. It does not rust or oxidize. For this reason, bare copper wires find extensive application in marine appliances.

Compatibility: Majority of the electrical manufacturers prefer using bare copper strips in appliances. So if you are installing wires at homes, use copper to maintain compatibility. Using wires of any other material can lead to galvanic reactions and therefore prove to be dangerous. So it is better to avoid risks and use copper.

Durability: Bare copper strips are also durable and last long. So if you are installing copper wires, you do not need to worry about going for frequent repairs.

Read: Copper Properties and Applications

Bare copper strips are also unaffected by weather fluctuations and are non-magnetic in nature.

All these properties explain why bare copper wires are so extensively used.

In contrast to bare copper wires, there are bunched copper wires where many small gauge wires are braided and compressed together. They are coated with some non-conductive material and twisted to produce loops.

These bunched wires are easier to install than bare copper wires. Bunched wires have a high resistance to corrosion and become hard on bending. Bunched wires find applications in headphone cables, speakers, and automobiles. Bunched wires also ensure smooth connections and help cables perform optimally without hassle.

While purchasing bare copper wire or bunched copper wire, you should keep certain things in mind. Always ensure the supplier you are buying from is reliable and has a proven track record. The supplier should also comply with all the rules and regulations of the industry.

Try to get feedback from other customers. Make sure the supplier has customer-friendly exchange policies so that any defective material can be returned without much hassle.

In case you are looking for more information related to bare copper wire or bunched copper wire, please mail us at info@rajasthanelectric.com.

Why are PVC Insulated Wires Needed by Electrical Industries?

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PVC insulated wires or the Polyvinyl chloride wires are extensively used for making cables. They are used for insulation purposes and for sheathing and bedding purposes. With the years, PVC insulated wires have started replacing the rubber insulated wires which were used for household wiring needs. These PVC wires are easier to process and they are very cost-effective. They last longer, more than 30 years.

Continue reading →

Why Is The Aluminum Rod In Demand Among Electrical Goods Manufacturers?

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The aluminum rod is known for offering a high degree of resistance to corrosion and weldability, making it popular for electrical goods manufacturers. Besides, the high strength rods can also be used in making aerospace applications. The corrosion-resilient aluminum round rods are ideally suited for marine applications because these are exposed to water all the time. Continue reading →

Why tinsel copper wire the most preferred metal?

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Tinsel wire is a low voltage electrical wire that is used mainly where high power-driven flexibility is essential. Generally speaking, it is most commonly used in the wires that are used in telephones, particularly the handset cords, and in headphones. As tinsel wires are quite malleable it is resistant failing because of metal fatigue relatively to normal stranded wire or solid wire. It is usually made up of copper.

Tinsel Copper wires are used in different industry rather being restricted to electrical industry. These wires first undergo a processing through tinsel tin, tinsel Silver, silver platted copper, cadmium copper and electrolyte copper. During this processing procedure these wires are flattened and covered with thread, including cotton, nylon, silver, nomex and Kevlar. But, this all depends on the requirement of the customers.

Let’s have a quick glance at the key applications of tinsel copper wires:

It is largely used in the fabrication of Speakers

It is extensively used in the manufacturing of Loudspeakers

It is used in the Tweeters coils

It is also used in the creation of Telecom cable

There are numerous of manufacturers that are manufacturing different types of Tin coated copper wire, and tinsel copper wire. Try to look for the right supplier!