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Copper Wire bunching

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3 years 1 month ago - 3 years 1 month ago #2911 by Mr Samantha Bandara
Hello Experts,

I am just a beginner for wire and cable industry.
Peoples are always saying that copper bunching process is the key for quality good wire. But they are failed justify that :-) .

I have 3 problems

1. How does bunching effect the final cable quality?
2. What are the characteristics of good quality bunch?
3. How we measure the quality of bunching process and bunched wires?

Please help me to improve my know-how.

Regards,
Samantha.
Last edit: 3 years 1 month ago by Peter J Stewart-Hay.

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3 years 1 month ago - 3 years 1 month ago #2913 by Peter J Stewart-Hay
Copper bunching is a very good and economical method of producing smaller gauge copper conductor for something say like multi-strand house wire.. The double twist bunching process produces a poorer quality conductor so stay with single twist bunching machines.

To answer your questions:

1 - Properly manufactured bunched strand will produce good cable quality.
2 - Properly bunched strand will have no wires sticking up, no broken wires and no kinks in the wires or the conductor.
3 - Mechanically speaking, I have already given you the answers. Electrically speaking, there are no issues so long as the conductor has the proper dimensions and conductivity.

I also suggest you visit WAI Store on the left hand side of this page and purchase the Nonferrous Wire Handbook, Vol. 3. This will be a really great reference for you.

Regards,
Peter J. Stewart-Hay Principal
Stewart-Hay Associates
www.Stewart-Hay.com
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Last edit: 3 years 1 month ago by Peter J Stewart-Hay.
The following user(s) said Thank You: Mr Samantha Bandara

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3 years 1 month ago - 3 years 1 month ago #2914 by Mr Samantha Bandara
Hello Peter,

Thanks for sharing your knowledge.

One more question,

How do we maintain the quality of the bunched wires? What are the factors we should adjust? Like conductor tension, etc?

Regards,
Samantha.
Last edit: 3 years 1 month ago by Peter J Stewart-Hay.

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3 years 1 month ago #2915 by Peter J Stewart-Hay
Hello again,

When you are bunching wires make sure:

- The mechanical properties of the wires are all the same. (Diameter, degree of anneal and so on.)
- The pay off tensions are all the same.
- The angles from the pay offs to the buncher are gentle and very similar. (No kinks or broken wire.)

Regards,
Peter J. Stewart-Hay Principal
Stewart-Hay Associates
www.Stewart-Hay.com
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The following user(s) said Thank You: Mr Samantha Bandara

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3 years 1 month ago #2916 by Mr Samantha Bandara
Hello Again peter,

Sorry for bothering you repeatedly.

Could you share us with some good practices, rule of thumbs, etc. related to copper wire bunching which helps to improve the bunched quality.

Thanks again,
Samantha.

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3 years 1 month ago - 3 years 1 month ago #2917 by Peter J Stewart-Hay
Hello again,

Please see the comment on my first post. (2913)
Thank you.

Regards,
Peter J. Stewart-Hay Principal
Stewart-Hay Associates
www.Stewart-Hay.com
This email address is being protected from spambots. You need JavaScript enabled to view it.
Last edit: 3 years 1 month ago by Peter J Stewart-Hay.

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