Continuous wiring or flexible cable is specially designed to withstand bends of significant radii and mechanical stresses associated with mobile devices (eg holders). Most often, a flexible cable is used to connect welding machines, generators, heat guns. It is in great demand on construction sites when it is necessary to stretch power lines.
Content
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Construction characteristics
- Midwife model
- Twisting into a bun
- Rigid and flexible conductors
- Household use
- Wiring in electrical installations
- Other information
Construction characteristics
In the 1980s, special attention began to be paid to the requirements in the field of automation technology. Due to the increase in loads, the movement of the cable along the construction site, core breaks have become more frequent. To solve the arisen problems, specialists have developed a flexible wire with unique characteristics that differ from standard analogs.
The highest level of flexibility indicates that the product's lifespan is significantly extended: the standard model allows 50,000 cycles, for analogs for the dynamic mode of use - 1-3 million cycles.
From a structural point of view, flexible wiring consists of the following elements:
- copper core;
- rubberized insulation;
- rubber sheath.
A synthetic film may be present in the wiring, which is used as a separation layer. It is applied to the conductors, but before the installation of rubberized insulation. The manufacturer can cover the twisted cores with synthetic foil if it is necessary to apply hose rubber later.
Types of flexible conductors:
- with layer-by-layer placement of pairs of veins, while the direction of the twist is different for each subsequent layer;
- with pairs of veins twisted into bundles.
Network wiring is available in a wide range of cross-sections. It can be used in various industries and in environments with high fire safety requirements. It is laid in harsh areas, while easily withstanding the effects of diesel fuel, gasoline.
Midwife model
This twisting of the veins is easy, so it is cheap. The veins themselves are tightly twisted into groupsthat are in the core. On top of the product, a belt insulation with a sheath is provided. In the twisting model, when bent, the inner radius decreases, and the outer one increases. At the beginning of work, this phenomenon is considered normal, which is associated with sufficient elasticity of the product. With prolonged bending, the material “fatigues”, causing irreversible deformation. In this case, the conductors are bent.
Stretch and compression areas appear. This can lead to a "coiled" appearance of the wire and breakage of the core. All these nuances are recommended to be taken into account before the start of electrical work.
Twisting into a bun
The veins, twisted not into layers, but into bundles and around an impenetrable elastic core, are produced using a unique technology. By eliminating stranded layers, an equal radius is guaranteed when bending any conductor: the line of action of the core moves rapidly from the inside to the outside of the wire.
The result of this production technology: the veins do not shrink or stretch. This reduces the overall load. The outer sheath prevents the core from unwinding.
In a bundled cable, sheath filling pressure is preferred. It fills in the gaps between the veins, preventing them from unwinding. In the veneer model, the pressed casing plays a primary role. Dynamic wiring is stiffer than standard wiring. But the product in question lasts longer in the mechanism, where its frequent bends are observed.
Rigid and flexible conductors
Before carrying out electrical work, experts recommend determining the type of wiring: rigid or flexible. The first product, unlike the second, is solid, that is, it consists of 1 conductor.
Solid wiring is designed to bend to a certain amount, after which the conductive core breaks. For example, a copper cable can withstand up to 80 bends, and an aluminum cable up to 12 times. During the period of operation, the resistance to fracture decreases significantly.
Therefore, experts advise using flexible conductors to connect mobile electrical receivers. Rigid wiring is laid if the electrical receiver, which is connected to the network, is in a strictly fixed position (does not move constantly).
Household use
Electrical wiring in the house, apartment and office provides power to switches, sockets, lighting devices. The listed elements are strictly fixed, therefore, a rigid cable is used for electrical work.
In the process of choosing the type of cable, experts advise taking into account the material and time costs required to perform turnkey electrical work.
Pros of flexible wiring:
- Simple installation in grooves.
- Quick installation in panel and junction box.
When connecting such a cable to different lighting devices, it becomes necessary to terminate its veins. For this, a special crimp tip is used or soldering is carried out. For the installation of electrical wiring with flexible conductors, additional funds will need to be allocated for the purchase of crimp terminals and the corresponding tools. For the price, flexible cable is more expensive than rigid cable. These nuances must be taken into account before starting work.
Pluses of solid wire:
- connection of cores immediately after removing the insulating layer;
- there is no need for preparatory work;
- when connected in a junction box, solid wiring is easily welded or crimped with sleeves.
The flexible cable, which is used for the installation of electrical wiring in the house, office, apartment, is highly resistant to breakage with its frequent reconnection in case of replacement of lighting fixtures. If you install reliable sockets, lights and switches, use a high-quality shield, and comply with the conditions for the correct operation of the electrical network, the rigid cable will be able to serve for a long period.
Wiring in electrical installations
In industrial enterprises, to connect stationary equipment, auxiliary circuits for various purposes, use a rigid cable. Flexible wire in electrical installations is used to connect circuits inside the switchboard, in the relay protection cabinet and automatic machines.
The choice of the cable type depends on the design of the element to be connected to the system. Flexible conductors are used to connect the secondary circuit to the microprocessor. If hard wiring is used in this case, the clamps on the device could be damaged.
The flexible cable can be used in the workshop to connect mobile electrical equipment, a welding unit and other device, the position of which is not fixed. The same product is used to power a separate movable unit - an element of a machine tool or other equipment.
Solid wiring is not laid if it provides for a bend under a small radius. When choosing between flexible and rigid cable particular attention is paid to the flexibility class. The higher it is, the better the wiring flexibility. For a solid cable, 1 class of flexibility is characteristic, and for a flexible cable - 7 class.
Other information
Experts carry out flexible and fixed installation of power, lighting and distribution networks, connect various mobile machines and mechanisms that operate with voltages up to 10 kW, using flexible cable. It can also be used to transfer data and signals from the sensor to the measuring unit, to organize a control circuit that operates at a frequency of up to 1 MHz.
The conductive flexible cable is made of tinned and copper wires, which complies with GOST. The product is available with one or more cores. Conductive structures are insulated in the form of polyvinyl chloride plastic. This material is not subject to combustion. Rubber, a halogen-free polymer composition can be used as insulation.
Insulated conductors are twisted into a core, pair, quadruple. A screen made of copper wire or alumoflex is superimposed on top. The temperature at which a flexible cable can be operated depends on the type of insulating material, outer sheath. On average, the value of this indicator ranges from -60C to + 70C.
