HOW ARE ELECTRICAL CABLES AND WIRES MADE?

HOW ARE ELECTRICAL CABLES AND WIRES MADE?
Over the course of a year, the electrical sector uses miles and miles of cable of all shapes and sizes. Most of us will just collect these finished products from our local wholesaler or supplier without ever wondering how they actually got on the shelf. A few months ago we visited Doncaster Cables to install a set of 4 different EV changers (you can check out that video from the link below) while we were they Doncaster Cables very kindly showed us around their astonishing facility, and just how they turn copper reel into the everyday product we as electricians know very well. Join us as Jordan walks you around the amazing factory that is the heart and soul of keeping electricity flowing in the UK.

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[artisanelectrics]

Leave a like if you want to see more videos like this! 👍

[Doncaster_Cables]

It was great to host you at our site for a few days! We hope you enjoyed our factory and got to see a lot about how we manufacture cables!

[ahmadazdin]

Honestly, I have been working in the field of electrical cables for a long time, and your explanation of the meaning of producing these cables is good and clear. I hope one day to move to America or Germany, like me. Thank you.

[radders]

Would love to see more tours of factories which make the stuff you use as an electrician.

This was a fantastic video by the way!

[andylombardi]

I served my electrical apprenticeship with Pirelli General Cables at their Eastleigh plant back in the early 70s. Principles of manufacture are much the same although process machinery is more compact. We started with copper ingots though.

[tomdeane]

Amazing video! As an electrician it’s an amazing view to see how the cables are actually made

[iluvtaters]

Its quite similar to how telecoms cables are made. I had the pleasure of visiting the BT cables factory in Manchester (now the British Cable Company) a few years ago. They start off with the same raw copper and can turn it into anything from aerial cable, armoured and 5000 pair. Really was amazing.

[minjgjp]

I used to work for British Ropes aka Briden and fibres during the 1984 but when the coal strike took off over 1 year my first job was in jeapordy but luckily a American company called Philip Morris saved the day . There was a electrical company in Slough making cables for power transmission.

[whatevernamegoeshere]

A bit of insight.
1:54 It is not actually stretched on the wheels. This is a SAMP insert drawing machine, those tooling holders between the wheels are diamond or carbide inserts that are funnel shaped and slightly smaller each time. The copper is pulled through those tool inserts by the wheels which only act as capstans between the stages. This is a relatively new construction as it is more compact, older machines used vertical drums in a row and only the drawing tool was oil submerged, while in this case the entire machine is just absolutely soaked inside. The oil is also used to absorb the heat and they have a heat exchanger hooked to it with a water circuit.
2:40 That machine is called the double twist buncher. It is basically the same as Kabmak's DTB. It has a carbon brush hell in the center as the "bow", the carbon fiber arch has to spin around the whole thing and and since it has a beefy capstan motor and a tensioning motor in there, if you skip maintenance it tends to blow up lol. The capstan portion is also equipped with a carbide insert to compact the cable and turn the strands into trapezoidal cross sections to make it thinner by a decent amount while keeping flexibility.
At 5:01 you can see that feed-throughs at the traversing parts are made of artificial ruby or similar ceramics to fight the wear. Notice the pinkish colour.
The machine at 5:15 is a drum twister. I don't think I have to say more lmao
5:24 That plexi window portion in the middle is the ribbon spinner, it spins around with one or two rolls of tape at multiple times the RPM to wrap it and make it round. It reduces the amount of plastic the extruder needs and makes the cable perfectly round in the end.
5:45 is the caterpillar. It's 2 belts that squeeze the cable to keep tension. There is one at the other end too. They are also the length counters.

[nmccw]

Excellent video Jordan. Thrilled to see the industrial might of Doncaster is still producing leading edge technology.

[vmotors.]

Stuff Made in the UK is what I like to see, and use.

[RobertJones-prrh]

Absolutely fascinating, often wondered how it's done. Thanks so much for showing us around. I've saved this one to watch again later. I'm sure you enjoyed the day too.

[davidrolfe]

Worth pointing out that the insulated cores are twisted around each other before sheathing for flexibility of the finished cable - when cable is bent the longer section of the twisted core on on the outside of the bend lengthens as the section of the core on the inside shortens. Having said that it looks like the insulated cores of that black sheathed multicore cable in the video had been laid up with uneven tensions judging by the `wobbly` sheathed appearance.

[brianhewitt]

having your company name printed on the cable was really cool, i can see a market for that and potentially a requirement

[jeanrobertwongtitshing]

i have worked in a similar place in Mauritius, Plasmo co ltd in year 80s. At the end of the process, testing is made in those bundle of cables to check for any cracks in the pvc insulation where high voltages are injected in those bundles placed in large pool full of water. I could see the bundle of cable shaking up and down, agitated the water everytime the voltages are injected. At the end of the testing a worker would come up with a rod cabling to earth to drain the voltage back to the ground before any handling is carried out.

[RespectthePhilippines-uueq]

Very interesting indeed. I once installed some nitrogen compressors and generators at a company called Elsewedy cables in Syria, they make heavy SWA. I think the nitrogen was used to stop the plastic inner sheathing sticking to the inner but I'm not sure. The compressors pressure settings were 350 bar

[troyboy]

This place is 10mins drive away from me ... It is truly a wonder of British graft and dedication .... brilliant !

[gordonm]

How do you make copper wire? Hand a Scotsman 2p and try and grab it back. I am Scottish and I can confirm this ;-)

[abdullahseba]

Very intresting, but would have been nice to hear the actual machines instead of the music... No need for mooosic when there's sound already! Would definitely like more videos like this though.

[BarneySaysHi]

You're giving the Discovery Channel's How It's Made a run for its money!