A cable is an assembly that connects two devices to transmit electrical signals and is formed by bonding, twisting or braiding two or more wires together. A cable is a collection of wires used to transmit power, data or signals. Cables have a wide range of uses and each use needs to be specially made. Its functions range from the transmission of electrical energy, electrical signals and wire products for the conversion of electromagnetic energy.Cable Assemblies

 

Power cables usually consist of a core for transmitting power or electrical signals and a sheath for protection and insulation. A wire without an insulating sheath is called a bare wire. A cable with only one core and a smaller diameter is usually called a wire. The core in the cable is made of a metallic material that conducts electricity well, usually copper, which is a good conductor, or aluminum, which is less expensive.

 

Ⅰ. Commonly used metal materials for cables

 

1. Copper: second only to silver in electrical conductivity, second only to gold and silver in thermal conductivity; anti-corrosion, non-magnetic, good plasticity, easy to weld, and widely used. Copper alloys are mainly used to improve the wear resistance, corrosion resistance and mechanical and physical properties of copper.

 

2. Aluminum: The electrical conductivity is second only to silver, copper, and gold; it has good thermal conductivity, good corrosion resistance, general mechanical strength, good plasticity, and small specific gravity. The disadvantage is that the tensile strength is low and it is not easy to weld. Aluminum alloy is mainly to improve the mechanical strength, heat resistance and weldability of aluminum.

 

3. Silver: The metal has the highest electrical conductivity and thermal conductivity, has good corrosion resistance and oxidation resistance, and is easy to weld; it is mainly used for coating and cladding; it is mainly used as high temperature resistant wire and (Note: According to the principle of skin effect ) is used as a high-frequency communication cable conductor.

 

4. Nickel: used as high temperature resistant wire.

 

5. Gold: used as high temperature resistant wire.

 

6. Zinc: used as the coating of steel wire/steel strip/iron conductor to prevent corrosion.

 

7. Tin: It is used as the coating of steel wire/copper wire to prevent corrosion and facilitate the welding of copper wire.

 

8. Iron: It is often used as a reinforcing material for composite conductors, such as steel-cored aluminum stranded wire, copper-clad steel, aluminum-clad steel wire, etc.

 

Ⅱ. Types of cables

 

1. Nuclear grade cables: suitable for control and signal connection cables used in the control system network of nuclear power plants with a rated voltage Uo/U of 0.6/1kV.

 

2. Flame-retardant rubber-sheathed cables: Flame-retardant rubber-sheathed cables are a series of rubber-sheathed soft cables for mine use. It is suitable for power connection of shearers and similar equipment with a rated voltage Uo/U of 1.9/3.3KV and below, and is mostly used in coal mines. The long-term allowable operating temperature of the wire core is 65°C, and the minimum bending radius of the wire is 6 times the diameter of the cable. Yellow sheathed cables must not be exposed to sunlight for long periods of time.

 

3. Power cables: cables used to transmit and distribute high-power electrical energy in power systems. It is mainly used for the transmission of strong electric energy in power generation, distribution, transmission, transformation, and power supply lines. The passing current is large (tens of amps to thousands of amps), and the voltage is high (220V to 500kV and above).

 

4. Bare wires and bare conductor products: the main features are: pure conductor metal, no insulation and sheath layer, such as steel-cored aluminum stranded wire, copper-aluminum busbar, electric locomotive wire, etc.; the processing technology is mainly pressure processing, such as Melting, calendering, drawing, stranding/compression stranding, etc.

 

5. Flexible fire-resistant cable: good safety, the fire-resistant cable not only supplies power normally in the flames, but also activates fire-extinguishing equipment to reduce fire losses. At the same time, it is also particularly reliable for personal safety. Its copper sheath is a good conductor and the best grounding wire, and it continues to the entire length of the cable, which greatly improves the sensitivity and reliability of grounding protection. Long service life, inorganic insulating material, high temperature resistance, and not easy to age, its life is many times longer than that of organic insulated cables.

 

6. Communication cables: cables used to transmit electrical signals (such as telephone voice signals, TV image signals, network communication signals, etc.). Common such as telephone cables, coaxial cables, network cables, etc.

7. Network cable: There are three commonly used network cables: twisted pair cable, coaxial cable and fiber optic cable (or optical cable for short).

 

8. Cables for electrical equipment: installation lines and control lines for assembling equipment, etc. Such as civil wires, control cables, instrument wires, electronic wires, heating cables, thermocouple compensation wires, etc., usually have requirements for the maximum outer diameter of the product.

 

Ⅲ. Application of cables

 

1. Power system

 

The wire and cable products used in the power system mainly include overhead bare wires, bus bars (bus bars), power cables, branch cables, electromagnetic wires, and electrical equipment wires and cables for power equipment.

 

2. Wind and solar power generation

 

In the field of renewable energy, cables are used to connect wind turbines and solar photovoltaic panels, feeding the generated electricity to the grid.

 

3. Control system

 

Cables are used in control systems to transmit signals and control currents in the fields of automation and industrial control. For example, industrial automation systems, robotics, and instrumentation all use cables to connect sensors, actuators, and controllers.

 

4. Information transmission

 

The wires and cables used in the information transmission system mainly include local telephone cables, TV cables, electronic cables, radio frequency cables, optical fiber cables, data cables, electromagnetic wires, power communication or other composite cables, etc.

 

5. Medical field

 

In medical equipment and medical devices, cables are used to transmit signals, control equipment and supply power. For example, electrocardiographs, blood pressure monitors, and medical imaging equipment are all connected using cables.

 

6. Instrument system

 

Except for overhead bare wires, almost all other products in this part are used, but mainly power cables, magnet wires, data cables, instrumentation cables, etc.

 

7. Automobile industry

 

Cables are used in automobiles to transmit power and signals, and to connect various components and systems of the vehicle, such as engine controls, in-vehicle entertainment, and body electronics.

 

8. Architecture and construction

 

In the construction industry, cables are used in the electrical installations of buildings, including lighting, electrical sockets, security systems and building automation, among others.

 

Ⅳ. Working principle of cable

 

The working principle of cables involves both signal transmission and current transmission, depending on the type and use of the cable.

 

1. Signal transmission:

 

Signal transmission cables are mainly used to transmit signals such as data, sound or images. The conductors of the cable carry the signal current or signal voltage. The insulation around the conductors acts to stop signal leakage and reduce interference. For shielded cables, the shield further blocks external interfering signals. The quality of signal transmission depends on factors such as the cable's frequency response, transmission loss, and interference suppression capabilities.

 

2. Power transmission:

 

When a power source is connected to the conductors of a cable, current flows from the source into the conductors, through the cable to the load. Electricity flows inside the conductor, and the insulation prevents the current from leaking to the outside environment. The resistance of the conductors will produce a certain voltage drop, but this voltage drop is acceptable within a reasonable range. The larger the conductor cross-sectional area of the cable, the lower the resistance and the more efficient the power transfer.

 

Ⅴ. Computer cable

 

Computer cables refer to various cables used to connect computers and their peripheral devices. They play the role of transmitting power, data and signals in the computer system to realize the connection and communication between the computer and external devices. Common computer cables are:

 

1. Data cable:

 

USB cable: used to connect the computer and external devices, such as printers, keyboards, mice, cameras, etc. USB cables have different plug types, such as USB-A, USB-B, Micro USB, and USB-C, choose the appropriate USB cable according to the interface requirements of the device.

 

Ethernet cable: used to connect a computer to a local area network or the Internet for network communication and Internet access.

 

HDMI cable: used to connect a computer to a monitor, TV or projector, etc. The HDMI cable transmits high-definition audio and video signals.HDMI Cables Belden Wire & Cable

 

DVI: Used to connect a computer and a monitor, and supports digital signal transmission.

 

2. Audio cable:

 

3.5mm audio cable: used to connect the computer with speakers, earphones or external audio equipment. The most common is a 3.5mm stereo plug, and sometimes a 4-pole jack with a microphone.

 

RCA cable: used to connect computer and audio equipment, such as audio, speakers, etc.Audio Cables / Video Cables / RCA Cables

 

3. Power cord: used to connect the power supply of the host computer and monitor and other equipment. Usually an AC power cord that connects one end to the appliance's power jack and the other end to a wall outlet.

 

Ⅵ.HDMI cable

 

HDMI cable is a digital interface standard for transmitting high-definition audio and video signals. It is widely used to connect various devices such as TVs, monitors, projectors, computers, game consoles, Blu-ray players, and audio-video receivers, etc.HDMI Cables

 

HDMI cables have the following features:

 

1. High compatibility: The HDMI standard has high compatibility and can be compatible with a variety of devices and manufacturers.

 

2. High-definition transmission: HDMI cable supports high-definition video transmission, including standard high-definition and full high-definition and other resolutions. It can provide clearer and more detailed image quality.

 

3. Single cable transmission: The HDMI cable can transmit audio and video signals through a single cable, avoiding the complicated wiring of multiple cables.

 

4. High bandwidth: HDMI cables have high bandwidth transmission capabilities and can handle high resolution and high frame rate video signals, as well as high bit rate audio signals.

 

Ⅶ. Cables can be divided into DC cables and AC cables according to the photovoltaic power station system

 

1. DC cables: DC cables are used to transmit DC power. Direct current is a current in which the direction of flow is constant, and charge flows in one direction in a circuit. DC cables are commonly used to connect DC power sources and load devices such as batteries, solar systems and electric vehicles.

 

2. AC cables: AC cables are used to transmit alternating current. Alternating current is current that changes direction periodically, with charge flowing back and forth in a circuit. AC cables are commonly used to connect power grids and various electrical equipment, such as household electricity, industrial electricity, and power transmission.

 

Ⅷ.D-Sub Cables

 

D-Sub cables are a common type of cable used to connect computers and other devices such as monitors, printers, serial devices, and more. D-Sub refers to a D-Sub connector, which has a D-shaped shape, in which multiple pins or connection pins are drawn out.D-Sub Cables

 

There are two types of D-Sub cables: VGA cables and RS-232 cables:

 

1. VGA cable: VGA D-Sub cable is used to connect computer and monitor. It has a 15-pin connector, 3 of which are used for the transmission of RGB (red, green, blue) analog video signals, and the other pins are used for power supply, synchronization signal and ground wire.

 

2. RS-232 cable: RS-232 D-Sub cable is used to connect computers and serial devices, such as modems, serial printers, barcode scanners, etc. It has a 9-pin connector, some of which are used for data transfer, others for control signals and ground etc.

 

Frequently Asked Questions

 

1. What is the environmental impact of cable manufacturing and disposal?

 

The materials used in the cable manufacturing process can have an impact on the environment. For example, the extraction and processing of metallic conductors can generate significant energy consumption and wastewater discharge, putting pressure on natural resources and water sources. Insulation and sheathing materials may contain hazardous substances such as chlorides, bromides and plasticizers, which can have environmental and human health impacts if not disposed of properly; the manufacture of cables requires a large amount of energy, including electricity and fuel. The harvesting and use of energy can lead to the release of carbon dioxide emissions and other greenhouse gases, with impacts on climate change and air quality.

 

2. When the cable is faulty, how to identify and troubleshoot?

 

First, check the physical connection of the cable. Make sure the cable is securely connected and the plug is intact. Sometimes, a loose connection or a damaged plug can cause signal interruption or power delivery problems. If the cable is used for power transmission, check that the power supply is normal. Make sure the electrical outlet is working properly and the power cord is not broken or damaged. If the cable is used for signal or data transmission, test instruments or equipment can be used to check parameters such as signal quality, data transmission rate or signal strength.

 

3. How to install the cable correctly?

 

Planning and design is critical before starting to install cables. Determine the cable routing, length, required number and connection points, etc., taking into account factors such as current load, cable type and environmental conditions. Select the appropriate type and specification of cables according to actual needs. Considering factors such as the required voltage level, current load, environmental conditions, and application scenarios, select cables that meet standards and specifications. Before starting the installation, do your homework. Clean up and make sure the installation area is clean and clear of any obstructions. Install cable tracks or conduits in place to provide cable support and protection. Choose proper routing and routing to avoid crossing cables with other power sources, high temperature equipment, or sources of electromagnetic interference. Avoid rubbing or compressing cables against sharp edges, mechanical equipment, or heavy objects.