Manufacturing process

Production of copper and aluminum non-insulated conductors for overhead power transmission lines

Non-insulated conductors for overhead power lines are flexible stranded wires consisting of several layers of copper or aluminum wires of circular cross section. To increase the strength of aluminum conductors, there can be used carrying core of one or more wires of galvanized steel twisted together, which are superimposed over the current carrying coils of aluminum wires.

An important requirement for the data conductors is manufactured length, i.e. minimum conductor length without compounds (welds) separate twisted wires.

Production technology of our enterprise allows manufacturing of non-insulated conductor’s cross-section up to 1000 mm2 construction lengths of 1.5-3 km. We have the capability to produce conductors for special crossings remote sites using the power lines carrying steel core section 141-204 mm2 manufactured length of up to 4 km.

The ability to manufacture big volumes of products provides high-speed equipment: drawing (with acceptance wire twisting machines smack coil segments of a given length) and twisting machines of domestic and foreign production.

Upon request, the company produces non-insulated conductors of special versions for installation in aggressive environments (seashore, desert regions). In this case, the core of conductor or all of the internal helix is covered by protective coating, insulating wire from environmental impact.

Production of copper and aluminum winding paper-insulated wires

Our company manufactures a wide range of winding wires in paper insulation. These are wires round and rectangular cross-section with copper and aluminum conductive core, subdivided wires, wires with a heat-resistant insulation, wires with insulation from heat-stabilized paper with adhesive coating applied on both sides.

For the wires production high-quality special insulation paper of best global manufactures is used. To increase the mechanical stability of the subdivided wires, special insulation paper epoxy coated is used for production of separate cores, which provides bonding individual wires in the conductor with a special mode of drying or heat treatment transformer windings.

Imposition of insulation on the wire is made by special insulating machines in way of insulating paper taping. Modern equipment allows simultaneous isolation of separate units of divided conductors and the imposition of common (lap) insulation.

This provides the necessary insulation of adjustable density and high accuracy of wire dimensions.

At our company special devices were developed and installed on the insulating machines and that provides continuous quality flaw detection control of the conductors with wire isolation. These instruments were permitted to exclude the defects in the finished wiring products like burrs, cracks, cavities, scratches, etc.

Production of enameled conductors

For the production of enameled and paper-insulated conductors we use special enamel paints from foreign manufacturers. Enamel aggregates allow putting insulation in accordance with all technical requirements and providing consistently high quality products. Enamel insulation has a high dielectric strength and is resistant to various solvents, including transformer oil and refrigerants. Constant quality control of conductor insulation is ensured in enameling process.

Production of transposed conductors

«Zaporozhye Cable Plant» PJSC is the only enterprise in Ukraine that manufactures transposed winding conductors with enamel-paper insulated windings for powerful oil power transformers and reactors. Production of these conductors is performed on the cutting edge high-tech equipment. For the first time in Ukraine we produced transposed conductor with full gluing enameled wire, which provides high dynamic resistance of transformer windings.

Modern enamel aggregates allow to produce enameled conductors with insulation of high dielectric strength and resistant to various solvents, including transformer oil and refrigerants. A single operation is performed imposition enamel insulation and a special adhesive layer, providing complete bonding conductors during heat treatment finished transformers winding.

Manufacturing of transposed conductors is made on modern machines transposing domestic and foreign production, which make twist from 5 to 59 enameled wires in a rectangular flow section.

Transposing allows to get a great cross section of winding conductor (35-350 mm 2), which consists of individual insulated wires and provides low level of losses in the transformer windings. In the process of twisting the wires, it is superimposed paper insulation required thickness and making continuous monitoring of the insulation between enameled wires.

Production of heat resistance winding wires with glass fiber insulation

Copper and aluminum winding wires with glass fiber insulation are used for the manufacture of electric motors and winding machines which work in harsh conditions at high temperatures, overload and heating coils to 180-200°C, which results in high requirements to quality, technology and culture of production.

Application isolation is manufactured using special glass winding aggregates. This equipment generates two-layer winding insulation of glass filaments or glass polyester fiber. Imposed isolation drenches heat-resistant silicone based paints and baked in heating cells aggregates at temperatures up to 450°C. The baking varnish insulation becomes monolithic, gets high mechanical strength and moisture resistance. Fiberglass insulation impregnated with organosilicon skim varnish to keep long performance at elevated temperatures and mechanical loads.

Production of copper and aluminum wires

For the production of wires we use special high-quality copper or aluminum wire rod of high purity, achieved by continuous casting and rolling. Manufacturing is carried out by drawing, i.e. pulling rod through special dies of rectangular or circular shapes on modern draw equipment.

Manufacturing of dies performed at the enterprise according to modern technology, with high-purity surface of the wire and the accuracy of its size to 0.01 mm.

After drawing a wire has high rigidity, because the drawing process changes the crystal structure of the metal, and hardening increases electrical resistivity. To remove inner voltages, provide the required mechanical properties and high electrical conductivity, recrystallization annealing is performed in special conveying wire electric furnaces. Copper conductors are susceptible to oxidation, so annealed in an oxygen-free steam environment.

Production of contact conductors for rolling stock

Manufacturing method of contact conductors made of copper rod through drawing dies with shaped working channel. Dimensions of the working channel dies are designed so that in the process of drawing consecutive crimping conductor attached to a given standard cross-sectional shape and required values of strength and elasticity.

At our enterprise routes breakdowns for different sizes of contact conductor were developed, special equipment for drawing tool was produced, providing required characteristics for contact conductors.

Laying the conductors on the drum is carried out so that when unwinding the wires mounted in the catenary conductor fastening convenience provided in the jaws bearing structures.

Production of copper flexible conductors

Copper flexible non-insulated conductors and conductors with paper insulation designed for power supply of mobile users or for installation in areas with limited dimensions, as well as for copper flexible wire manufacture of current-carrying tap transformer windings. They represent the core of the bundles (strands) copper wires diameter 0,5-0,9 mm twisted right twist of several helix. Core cross-section is from 10 to 1000 mm2.

The wire of diameter of 0.5-0.9 mm is manufactured on special fine drawing equipment with a device annealing copper wire. Wire by twisting beam machines, manufactured strands, which were later twisted into a conductor on twisting machines.

Paper insulation of required nominal thickness (up to 20 mm) is applied to the conductor with special insulating equipment.

Product testing

One of the main principles of our company policy in quality is the manufacture, inspection and testing of the product by qualified, competent personnel.

Quality control and product testing are carried out in full volume and are regulated by the normative and technical documentation: acceptance testing, recurrent testing. The tests are performed in a certified laboratory. This means that the laboratory tests and quality control meet all the necessary criteria and are certified to conduct measurements during the determination of quality of conductors and wires products. Available test equipment and highly qualified staff are able to ensure that all necessary tests are performed and guarantee consistently high quality of our products.

In connection with the development of production of copper wires with transposed enameled wires are spliced in total insulation paper, additional modern test equipment purchased, including a unique tensile machine with programmed control and heat chamber for mechanical testing. This equipment allows to perform tests to determine the yield strength and the shear strength test between the enameled wires at normal and elevated temperatures.

We issue a certificate of quality for all range of products of our company.