EuroWire January 2024

Technology News

Efficient insulation and accurate spark test results

In the case of Delta Tecnic, 25 per cent of colour masterbatch sales are in the automotive industry – the sector that presents the most difficulty in obtaining satisfactory spark test results due to the use of shorter high-speed dilution machines. Industry requirements have led the company to design and control its masterbatches with the aim of reducing the faults detected by the spark tester. As the conductor cable, with its respective insulation, passes through the spark tester it is subjected to a high voltage electric field to detect any leaks. If an electrical reaction occurs, the device emits a warning signal. It is crucial to avoid the presence of large unwanted particles in the cable insulation. Holes may be caused by poor dispersion of the products used in the insulation mixture. Plastic insulation is made up of two materials: generally, 98 per cent is a polymeric compound either manufactured by the same cable manufacturer or supplied by companies specialised in compound manufacturing, while the remaining two per cent is the colourant provided. Both of these raw materials may contain particles that are poorly dispersed/incorporated into the polymeric mass, resulting in the formation of holes that will cause a failed spark test. A poorly manufactured masterbatch can be one of the causes of these holes, due to the presence of excessively large particles in the polymer. A masterbatch used in the cable industry should achieve the best possible pigment dispersion, which involves breaking the crystalline units that make up the pigments through a mechanical process using extruders, preventing them from remaining inside the masterbatch. Another possible fault relates to dilution. During cable manufacturing, the masterbatch might not be properly diluted in the customer’s compound, and the resulting large unwanted particles can cause holes in the insulation. If properly mixed, the masterbatch is fully compounded and melted into the polymeric base. However, in some cases customers may face difficulties in diluting masterbatches, as the cable industry is increasingly working with faster and shorter extruders that make this process more complex.

For the power cable industry, and especially in automotive cables, it is necessary to achieve total insulation of the electrical conductor (copper or aluminium, in most cases). The spark test aims to detect holes in the plastic layer covering the cable conductor. Even small holes can cause unwanted effects such as energy leaks and loss of electricity, creating serious problems in an electrical circuit. Medek & Schörner At wire Düsseldorf 2024, Medek & Schörner will showcase the customer benefits of its close collaboration with Austrian engineering expert KHU and the company 2M-Tech. Together, Medek & Schörner, KHU and 2M-Tech offer a complete range of advanced solutions for the cable and wire industry. Medek & Schörner will be exhibiting and demonstrating its latest developments, including a new optical fibre colouring line with production speed up to 3,200m/min. Read the full story in the March issue Ajex & Turner A-350 Pressure Holders are a valuable addiƟon to wire drawing processes, ensuring efficient lubricaƟon, compaƟbility with various die box configuraƟons, and long-lasƟng, reliable performance. These holders play a vital role in maximizing the quality of drawn wire while minimizing maintenance and replacement costs. Pressure Drawing Die, A-350 With Coating VNT Nano

Delta Tecnic designs masterbatches with the aim of reducing faults detected by the spark tester

The challenge for the masterbatch manufacturer is to achieve the best dilution possible, which requires an appropriate temperature and mixing process. “At Delta Tecnic we strive to provide solutions that drive the advancement of the cable industry and improve the quality of cables used in various sectors,” said Manuel Miret, area manager and new product developer. “Our focus on the optimal dispersion of pigments and the formulation of our masterbatches to achieve a perfect dilution is essential to guarantee the excellence of manufactured cables and optimal results in the spark test during manufacturing.” Delta Tecnic https://deltatecnic.com Aztech Lubricants LLC Aztech Lubricants is a provider of wire drawing and lubricant solutions. On its stand, the company will showcase the EZDraw, EZClean, EZCoat and EZFeed products, and its new cross-fusion drawing lubes. Aztech provides a full line of calcium-, sodium- and potassium-stearate based drawing powders, RP oil, drawing oils, vanishing oils and pre-coats, as well as a complete line of AZWipe spiral brushes. Aztech has manufacturing and distribution capabilities in the USA, Colombia, India and Korea. Read the full story in the March issue Roblon A/S Visitors to Roblon’s stand will have the opportunity to learn about the latest in performance fibres and machinery in FOC applications. Representatives will be available to introduce the company’s most recent developments for the cable industry and to discuss how Roblon solutions can help customers achieve fast and efficient production. The stand will also showcase a variety of performance fibres. The company has manufacturing bases in Denmark and the Czech Republic, and North Carolina, USA. Read the full story in the March issue

Die Body

Pressure Nib

Locking Body

VNT Nano Coated Drawing Nib

AJEX & TURNER WIRE TECHNOLOGIES PVT. LTD. info@ajexturner.com | sales@ajexturner.com www.ajexturner.com We also supply wide range of dry & wet Lubricants for carbon steels and stainless steels.

42

www.read-eurowire.com

January 2024