Technical information
HF stranded wires are manufactured from several individual enameled copper wires by twisting in accordance with
DIN 46447. For larger cables, different bundles of strands are combined with each other
. With this type of stranded wire/cable, the exact position of the individual wires is not defined.
To be fully effective, none of the fine wires must be interrupted. All wires
must be stripped at the ends and connected to the circuits. In this way
all individual conductors are connected in parallel. The higher quality in the high-frequency range is based
on the increase in the cross-section effectively involved in the current flow, which is limited in the solid wire
by the following effects: Skin effect
charge carrier displacement due to the magnetic field of the individual conductor. At high frequencies, most of the current flows along or near the surface of the conductor due to this effect. The loss resistance can be reduced by increasing the conductivity, especially of the surface, or by connecting many thin individual conductors (stranded wires) in parallel. Proximity effect
Charge carrier displacement to one side of the conductor by the magnetic field of a coil made from it, or currents running back and forth on both sides of the conductor due to an external time-varying magnetic field. Twisting direction
When stranding high-frequency stranded conductors, there is also the twisting direction parameter. It describes the direction in which the strand is twisted/twisted. A basic distinction is made between the lay directions S and Z.
Calculation of the nominal outer diameter of strands
The nominal outer diameter produced from individual enameled copper wires with textile braiding is determined approximately by the following formula.
Where : D = Nominal diameter of the insulated conductor (in mm) k = Compression factor n = Number of individual enameled copper wires d = Nominal diameter of an individual enameled copper wire
Number of individual enameled copper wires | Compression factor |
from 3 to 6 | 1,25 |
7 | 1,15 |
from 8 to 12 | 1,25 |
16 | 1,26 |
20 | 1,27 |
from 25 to 400 | 1,28 |
Measuring the strand diameter The strand diameter is the diameter of the circle drawn around the rope cross-section.
Lay length
The lay length of a specific strand layer in a wire rope is the pitch of the helical strands in this layer. Short lay length: high flexibility, good grip of the individual strands, better roundness of the strand. Long lay length: stiffer, less good grip of the individual strands, better fill factor. The lay length can be set between 1 mm and 500 mm. Possible tolerances ± 10% and ± 20% (standard). The specialists at the factory determine the lay length without your specifications.
HF stranded wires made of enameled copper wires (with and without additional insulation)
Conductor
Bare copper wires | Enameled copper wires | |
Copper cross-sections | up to 2000 mm² | up to 2000 mm² |
Diameter of a single wire | 0.032 to 4.00 mm = AWG 41 to AWG 6 | 0.032 to 4.00 mm = AWG 42 to AWG 6 |
Number of wires | From at least 9 x 0.023 mm ( 0.24 mm diameter) to several tens of thousands | |
MW 79 -155°C | IEC 60317-20 | |
MW 82 -180°C | IEC 60317-51 | |
MW 77 – 180°C | IEC 60317-23 | |
MW 30 -180°C | IEC60317- 8 | |
MW 35 – 220°C | IEC 60317-13 | |
MW 16 – 220°C | IEC 60317-7 | |
others on request | ||
Cable dimensions min. to max. | From 2.20 x 1.50 mm to 40.00 x 25.00 mm | |
Additional insulation |
Taping: Kraft paper or crepe, Nomex®, polyester, fiberglass mesh, fiberglass/mica or other tapes up to 20 mm thick on request | |
Braiding: 1 or 2 layers of cotton, nylon, polyester, artificial silk or Nomex®
Braiding: cotton, nylon, polyester or Nomex® |
||
Others: on request |
Banding
Type | Thermal class | Thickness | Designation |
Coated paper | |||
Kraft paper | 105°C | 50 to 125 μm | K 50 – K 60 – K 80 – K 100 – K 125 |
Heat-treated kraft paper or Insuldur kraft paper | 120°C | 50 to 10 μm | KI 50V – KI 80V – KI 100V |
Kraft paper with increased mechanical strength | 105 °C | 50 and 75 μm | M 50 – M 75 |
Kraft paper coated on both sides with epoxy in installment form | 120 °C | 90 μm | KDD 9 0 |
Crepe kraft paper fine-creped | |||
Coated on both sides with epoxy in installment form | 105 °C | 65 μm | CDE 50 |
Coated on one side with epoxy in installment form | 120 °C | 50 and 80 μm | KCI 12dn – KCI 22dn |
Crepe paper | |||
Crepe paper 80 μm 50 % creped | 105 °C | 315 μm | KC 105 |
Crepe paper 120 μm 90 % finely creped | 105 °C | 370 μm | KC 80 |
Crepe paper75 μm 100 % creped | 120 °C | 500 μm | KCI 100V |
Aramid paper | |||
Aramid paper | 180 °C | 50 μm | Nomex® 410-50 |
Aramid paper coated on one side with epoxy | 180 °C | 90 μm | Nomex® 410-80E |
Polyester | |||
PET film | 130 °C | 8 to 50μm | FP 08 – FP 12 – FP 19 – FP 23 – FP 36 – FP 50 |
Semi-conductive polyester tape | 155 °C | 180μm | PSC 180 |
Mica paper | |||
Mica paper on polyester film | 155 °C | 80 to 90 μm | MFPE 80 – MFPE 90 |
Mica paper on polyester film coated with epoxy on one side | 155 °C | 80 to 90μm | MFPE 80 – MFPE 90 |
Mica paper on glass fabric | 155 °C | 130μm | MVT 130 |
Polyimide film | |||
Polyimide film | 155 °C | 25, 40μm | Kapton® 100HN |
Polyimide film | 220 °C | 25, 40μm | Apical® |
Glass fabric tape | 220 °C | 100 to 200μm | VT 100 – VT 130 – VT 200 |
Cotton tape | 90 °C | 180 and 300μ m | JAC 2380/0.18 – JAC 2380/0.30 |
Wrapping or braiding with cotton yarn | 90 °C | 60 and 120 nm | Cotton 60 nm Cotton 120 nm |
HF stranded wires round
Dimensions:
Cross-sections up to 2,000 mm2 max. diameter 65 mm max. diameter of individual wires from 0.032 mm to 4.00 mm
HF stranded wire
For space reasons, it is sometimes necessary to profile strands to obtain a rectangular or square profile instead of a round one. The following must be taken into account here:
1 < | Wide | <3 | Effective copper cross-section | < 3 |
Height | Theoretical copper cross-section |
Please always specify which dimension (width or height) must be adhered to (before any additional insulation).
Dimensions: Cross-sections up to 470 mm2 max. profiling: 40 x 25 mm max.
Diameter of enameled copper wires according to IEC 60317-0-1
Nominal diameter | Nominal copper cross-section | AWG | Grade 1 | Grade 2 | |||||||
Diameter | diameter | ||||||||||
minimum | maximum | minimum | maximum | ||||||||
[mm] | [mm2] | [Circ. Mils] | [mm2] | [inch] | [mm2] | [inch] | [mm2] | [inch] | [mm2] | [inch] | |
0,063 | 0,0031 | 6,1521 | 42 | 0,066 | 0.0260 | 0,076 | .00299 | 0,073 | .00287 | 0,083 | 0.00327 |
0,067 | 0,0035 | 6.9581 | 0,071 | .00280 | 0,080 | .00315 | 0,076 | .00299 | 0,088 | .00346 | |
0,071 | 0,0040 | 7.8137 | 41 | 0,075 | .00295 | 0,084 | .00331 | 0,080 | .00315 | 0,091 | .00358 |
0,075 | 0,0044 | 8.7189 | 0,079 | .00311 | 0,089 | .00350 | 0,086 | .00339 | 0,095 | .00374 | |
0,080 | 0,0050 | 9.9202 | 40 | 0,084 | .00331 | 0,094 | .00370 | 0,091 | .00358 | 0,101 | .00398 |
0,085 | 0,0057 | 11.1989 | 0,090 | .00354 | 0,100 | .00394 | 0,097 | .00382 | 0,107 | .00421 | |
0,090 | 0,0064 | 12.5552 | 39 | 0,095 | .00374 | 0,105 | .00413 | 0,102 | .00402 | 0,113 | .00445 |
0,095 | 0,0071 | 13.9890 | 0,100 | .00394 | 0,111 | .00437 | 0,108 | .00425 | 0,119 | .00469 | |
0,100 | 0,0079 | 15.5003 | 38 | 0,105 | .00413 | 0,117 | .00461 | 0,113 | .00445 | 0,125 | .00492 |
0,106 | 0,0088 | 17.4161 | 0,112 | .00441 | 0,123 | .00484 | 0,120 | .00472 | 0,132 | .00520 | |
0,112 | 0,0099 | 19.4435 | 37 | 0,118 | .00465 | 0,130 | .00512 | 0,126 | .00496 | 0,139 | .00547 |
0,118 | 0,0109 | 21.5826 | 0,125 | .00492 | 0,136 | .00535 | 0,134 | .00528 | 0,145 | .00571 | |
0,125 | 0,0123 | 24.2192 | 36 | 0,132 | .00520 | 0,144 | .00567 | 0,141 | .00555 | 0,154 | .00606 |
0,132 | 0,0137 | 27.0077 | 0,140 | .00551 | 0,152 | .00598 | 0,150 | .00591 | 0,162 | .00638 | |
0,140 | 0,0154 | 30.3805 | 35 | 0,148 | .00583 | 0,160 | .00630 | 0,158 | .00622 | 0,171 | .00673 |
0,150 | 0,0177 | 34.8756 | 0,159 | .00626 | 0,171 | .00673 | 0,170 | .00669 | 0,182 | .00717 | |
0,160 | 0,0201 | 39.6807 | 34 | 0,169 | .00665 | 0,182 | .00717 | 0,180 | .00709 | 0,194 | .00764 |
0,170 | 0,0227 | 44.7958 | 0,180 | .00709 | 0,194 | .00764 | 0,192 | .00756 | 0,205 | .00807 | |
0,180 | 0,0254 | 50.2208 | 33 | 0,190 | .00748 | 0,204 | .00803 | 0,202 | .00795 | 0,217 | .00854 |
0,190 | 0,0284 | 55.9559 | 0,201 | .00791 | 0,216 | .00850 | 0,214 | .00843 | 0,228 | .00898 | |
0,200 | 0,0314 | 62.0010 | 32 | 0,211 | .00831 | 0,226 | .00890 | 0,224 | .00882 | 0,239 | .00941 |
0,212 | 0,0353 | 69.6644 | 0,224 | .00882 | 0,240 | .00945 | 0,238 | .00937 | 0,254 | .01000 | |
0,224 | 0,0394 | 77.7741 | 31 | 0,236 | .00929 | 0,252 | .00992 | 0,250 | .00984 | 0,266 | .01047 |
0,236 | 0,0437 | 86.3302 | 0,249 | .00980 | 0,267 | .01051 | 0,264 | .01039 | 0,283 | .01114 | |
0,250 | 0,0491 | 96.8766 | 30 | 0,263 | .01035 | 0,281 | .01106 | 0,278 | .01094 | 0,297 | .01169 |
0,265 | 0,0552 | 108.8506 | 0,279 | .01098 | 0,297 | .01169 | 0,294 | .01157 | 0,314 | .01236 | |
0,280 | 0,0616 | 121.5220 | 29 | 0,294 | .01157 | 0,312 | .01228 | 0,309 | .01217 | 0,329 | .01295 |
0,300 | 0,0707 | 139.5023 | 0,315 | .01240 | 0,334 | .01315 | 0,331 | .01303 | 0,352 | .01386 | |
0,315 | 0,0779 | 153.8013 | 28 | 0,330 | .01299 | 0,349 | .01374 | 0,346 | .01362 | 0,367 | .01445 |
0,335 | 0,0881 | 173.9517 | 0,351 | .01382 | 0,372 | .01465 | 0,369 | .01453 | 0,391 | .01539 | |
0,355 | 0,0990 | 195.3420 | 27 | 0,371 | .01461 | 0,392 | .01543 | 0,389 | .01531 | 0,411 | .01618 |
0,375 | 0,1104 | 217.9724 | 0,391 | .01539 | 0,414 | .01630 | 0,410 | .01614 | 0,434 | .01709 | |
0,400 | 0,1257 | 248.0042 | 26 | 0,416 | .01638 | 0,439 | .01728 | 0,435 | .01713 | 0,459 | .01807 |
0,425 | 0,1419 | 279.9734 | 0,442 | .01740 | 0,466 | .01835 | 0,462 | .01819 | 0,488 | .01921 | |
0,450 | 0,1590 | 313.8803 | 25 | 0,467 | .01839 | 0,491 | .01933 | 0,487 | .01917 | 0,513 | .02020 |
0,475 | 0,1772 | 349.7246 | 0,494 | .01945 | 0,519 | .02043 | 0,515 | .02028 | 0,541 | .02130 | |
0,500 | 0,1963 | 387.5065 | 24 | 0,519 | .02043 | 0,544 | .02142 | 0,540 | .02126 | 0,566 | .02228 |