EoW July 2007

english technology news

Going with the flow in the manufacture of non-ferrous components

Many of the advances in themanufacture of non-ferrous metal components over recent years have been through the replacement of discontinuous and batch production by continuous manufacturing processes. High conductivity copper profiles for transformer strip, commutator sections and busbars are produced conventionally by discontinuous billet extrusion, where a final draw pass is used to give the required temper in the finished product. Preparation of the billets themselves has advanced over the years from discontinuous stick moulding, through semi-continuous casting to continuous casting, each necessarily followed by billet heating, prior to extrusion. This sequence consists of a minimum of five individual process steps and a very high equipment cost. Billet extrusion is a notably inefficient process with yields not often exceeding 80%. For very high production volumes (15,000 tons per year and over) a modern version of this process sequence may still be competitive, but there is now an alternative route. A radically different combination of technologies, involving continuous casting of copper rod and continuous extrusion (Conform™) of profiles, is now available to produce these products.

Copper profiles for the transformer strip

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Rautomead Limited and BWE, both of the UK, are specialists in the technology of continuous casting and Conform continuous extrusion, respectively. Using grade A copper cathode as the feedstock, the copper is melted and continuously cast in a Rautomead RS upwards-vertical copper casting machine to produce rods of 8mm-20mm diameter, according to dimensions of the finished product required. The rods are formed into coils of typically 4 tons. The copper rod is oxygen-free with a nominal oxygen content of less than 3ppm, and is cast with a clean unoxidised surface. The cast rod is subsequently decoiled and fed directly to the Conform machine

which continuously extrudes the selected profile of fully soft, fine grain copper section. As in the traditional extrusion route, a final draw pass may be necessary to give the required temper in the finished product. Using this modern combination of technologies the number of process steps is reduced from five to three, and a claimed process yield of over 90% can be expected. Combined lines are available with capacities from 4,000 to 10,000 tons per year. Rautomead Limited – UK Fax : +44 1382 622941

Email : sales@rautomead.com Website : www.rautomead.com

High speed braider Using the latest technology, Shan-ghai Nanyang has produced the GSB-1Q 16-carrier high-speed braider. The machine is used for braiding of ultra-thin wires in industries such as micro-computer, movable communication installation, space flight and aviation.

Atom Kablo is one of the leading electric cable manufacturers and exporters in Turkey, who focus mainly on armoured steel wire (SWA), low voltage installation power and control cables and building wires. Using expertise gained over the years, the company has a proven commitment to quality, ongoing development of high value added products and improved productivity which helps maintain long-term business partnerships based on absolute confidence. Atom Kablo is capable of manufacturing PVC, PE, XLPE, HFFR insulated or sheathed low voltage cables, which are currently exported from the home city of Denizli to a number of European countries, Hong Kong, Singapore and Bangkok. l One of the leading exporters in Turkey

Braiding pitch ranges from 2-60mm which can be freely chosen at 0.1mm precision.

It can braid ultra- thin copper thread of 0.03-0.05mm, and the tension-constant take-up and pay-off mechanism ensures the braiding process keeps tension even. Shanghai NanYang Electrical Equipment Co Ltd – China Fax : +86 21504 29025 Email : sales@shanghai-nanyang.sina.net Website : www.shanghai-nanyang.com The GSB-1Q 16-carrier high speed braider ▲

Atom Kablo – Turkey Fax : +90 216 4670 439 Email : atom@atom.com.tr Website : www.atom.com.tr

An example of cables produced by Atom Kablo

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EuroWire – July 2007