EoW July 2007

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EuroWire – July 2007 48
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.
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:
Website :
Copper profiles for the transformer strip ▲
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.
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 :
Website :
The GSB-1Q 16-carrier high speed
braider
▲
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.
lOne of the leading exporters in Turkey
An example of cables produced by Atom Kablo ▲
Atom Kablo – Turkey
Fax: +90 216 4670 439
Email:
Website: