Interwire 2019

Interwire 2019
OUR DRIVING FORCE
ELECTRICAL LINEAR RESISTANCE VERSUS

WEIGHT MEASUREMENT OF CONDUCTORS –
WHAT BENEFITS CAN WE EXPECT?
BORIS DARDEL, VINCENT ARBET-ENGELS

AESA-CORTAILLOD, SWITZERLAND
Contact: B. Dardel. AESA, Plaine 7, CH-2013 Colombier, Tel: +41 32 843 03 99, Mobile: +41 79 477 05 09, bdardel@aesa-cortaillod.com
www.aesa-cortaillod.com 1
Interwire 2019
Introduction
Metallic conductors are usually the main source of cost in a cable

• High density and cost of metal as compared to plastic material
 Reducing these costs allows to save a large amount of money

 Trend : aluminum replaces copper.
DESIGN targeting subsequent

improvement LIMIT SAVINGS
Interwire 2019
Main Standards
IEC 60228 (“Conductors of insulated cables” )
• Min Number (class 2) / Max diameter (Class 5/6) of wires
• Linear electrical resistance: Measured
ASTM Standards B8-11 (“Standard Specification for Concentric

Lay-Stranded Copper conductors” - respectively B231/B231M-12
for aluminium)
• Wire number/dimension/lay length
• Conductor diameter
• Area: Calculated from wire dimensions or measured by weight
• Linear resistance: Calculated from area and material
resistivity or measured
Interwire 2019
Determination of conductor area (ASTM)

By weight
Cut the conductor

𝟏 𝑾
𝑨
𝑲𝑳 𝒇
where A = Conductor area
K = Correction factor for the wires overlengths due to stranding

𝑘
𝐾 1
Weight sample 100
with k = Increment of mass or electrical resistance
W = Mass of the sample

Calculate from design
L = Length of the sample
Measure sample length
f = Mass factor of the material (density)

8.890g/cm3 for Copper and 2.705g/cm3 for Aluminum 1350 at 20°C
Interwire 2019
Determination of conductor area (ASTM)
Uncertainty
K = 0.16% (deviation of the lay length of 0.01 x diameter of the layer)
W = 0.1% (as prescribed in the standard)
L = 0.13% (square distribution of +/- 1/32 inch over 2 feet)
f = Negligible
 A = 0.23%
Interwire 2019
Determination of Linear resistance (ASTM)

By area and resistivity
𝑲 𝝆 𝟐
𝑳 𝒇 𝝆
𝑹 𝑲
𝑨 𝑾
Measure area
where R = Linear resistance

𝝆 = Resistivity of the material
0.017241 mm2/m for 100%IACS at 20°C
Measure sample resistance
Considering the uncertainty on the resistivity given in ASTM B193-02
 = 0.3%
 R = 0.41%
Interwire 2019
Typical distribution
/500MCM
 = 0.4%
Interwire 2019
What about linear resistance measurement ?
Interwire 2019
On-the-line measurement: principle
𝑼
𝑹
𝑰
𝜌 𝜌 1 𝛼 𝑇 𝑇 where  = Resistivity
T = Measurement temperature
T0 = 20°C = Reference temperature
 = Temperature coefficient of the resistivity
0.393% for Copper and 0.403% for
Aluminum
Interwire 2019
On-the-line measurement: Practically
Interwire 2019
On-the-line measurement: Practically
• Measurement at 2.5 Hz  converted to DC (Synchronous

rectifiers)
 Allows to measure and control the current in conductor
• Temperature stabilization: sensors + heaters
Interwire 2019
On-the-line measurement: Performances
Measurement precision is
• Copper conductors:
• 0.1% up to 1000mm2/2000MCM
• 0.2% up to 1800mm2/3600MCM
• Aluminium conductors:
• 0.1% up to 300mm2/600MCM
• 0.2% up to 1200mm2/2400MCM
When using the heating system, these values may slightly increase,
depending on the selected stabilization parameters
Interwire 2019
Comparison
Resistance
Comparison Weighting method
measurement
Precision > 0.4% 0.1 - 0.2%
Need to cut the conductor Yes No
Dependent on material conductivity Yes No
Dependent on material density Yes No
Depending on stranding accuracy Yes No
Quick and easy No Yes
Interwire 2019
Relevance of the precision
Gaussian distribution
Interwire 2019
Relevance of the precision Savings
15.9%
1
0.3%
0.1%
3
0.9%
Interwire 2019
Conclusion
On-the-line linear resistance measurements

• Improves the efficiency of design validation and process
controls, integrating the effect of all the usually individually
measured parameters.
• The measurement takes only few minutes directly on the

production line without the need to cut the conductor.
Interwire 2019
Conclusion
On-the-line linear resistance measurements

• It can be repeated along the production for process control
or for design improvement.
• Permits a finer tuning of the conductor design, allowing

material saving.

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OUR DRIVING FORCE

ELECTRICAL LINEAR RESISTANCE VERSUS

BORIS DARDEL, VINCENT ARBET-ENGELS

Metallic conductors are usually the main source of cost in a cable

 Reducing these costs allows to save a large amount of money

DESIGN targeting subsequent

ASTM Standards B8-11 (“Standard Specification for Concentric

Determination of conductor area (ASTM)

Cut the conductor

where A = Conductor area

K = Correction factor for the wires overlengths due to stranding

W = Mass of the sample

f = Mass factor of the material (density)

Determination of conductor area (ASTM)

Determination of Linear resistance (ASTM)

where R = Linear resistance

Measure sample resistance

Considering the uncertainty on the resistivity given in ASTM B193-02

What about linear resistance measurement ?

On-the-line measurement: principle

On-the-line measurement: Practically

On-the-line measurement: Practically

• Measurement at 2.5 Hz  converted to DC (Synchronous

On-the-line measurement: Performances

Precision > 0.4% 0.1 - 0.2%

Need to cut the conductor Yes No

Dependent on material conductivity Yes No

Dependent on material density Yes No

Depending on stranding accuracy Yes No

Quick and easy No Yes

Relevance of the precision

Relevance of the precision Savings

On-the-line linear resistance measurements

• The measurement takes only few minutes directly on the

On-the-line linear resistance measurements

• Permits a finer tuning of the conductor design, allowing

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