Copper is used for cables around the world. Despite the introduction of newer technologies, copper wires and cables remain the most popular solution for carrying power, data and signals.
Advances in technology are offering designers alternatives to traditional copper wiring. Wireless systems such as WiFi, BlueTooth and 5G give users the freedom to move around. Untethered by traditional wires, wireless communications are enabling advances in a wide range of applications, especially in the industrial and automotive markets.
Optical fiber is a high-speed rival to traditional copper connectivity. Using pulses of light instead of electrical signals, fibers can transmit huge volumes of data over long distances with very low losses. The undersea cables that form the backbone of the internet use this optical technology. Despite these advances, traditional copper wires and cables remain the most popular solution for carrying power, data and signals as they offer several key advantages over their competitors.
The Proven Performance of Copper
Copper has been used for electrical circuits for two centuries, and with the rise of telegraphs in the late 1800s, copper became the preferred material for cables. With such a long track record, copper has proven its reliability many times over. Copper is an ideal material as it offers a unique balance between cost and performance. Precious metals including gold and silver offer similar electrical conductivity, and they are frequently used in small amounts as plating for electrical contacts. However, their cost means that cables made of these materials would be hugely expensive. Copper is far more plentiful and therefore offers a price advantage.
The characteristics of copper also make it suitable for constructing wire and cable. It is a strong yet ductile material which means it can easily be drawn into long wires. Once formed it remains flexible, and the mechanical qualities of copper wiring have been proven to deliver long term reliability in even the toughest conditions.
Another clear advantage over wireless or optical technologies is the electrical conductivity of copper and its ability to deliver power. Despite ongoing research, the reliable delivery of power using wireless technology is restricted to very short distances. For most situations, this short range is impractical, and designers depend on copper to provide the link between the power source and the user.
Copper and Smart Technology
Copper will therefore remain in use for many years to come. However, copper cables are facing increasingly challenging conditions. For many years, computer networking was confined to the easy conditions of the office, away from harsh environments or the rigors of the factory floor. However, a number of trends are witnessing the extension of networks into demanding locations.
The smart factory, powered by the Internet of Things (IoT), allows machines to share data around the facility, creating a production process that is adaptable and efficient. The smart factory depends on reliable connectivity between machines and control automation.
This smart revolution will see machinery installed beyond the factory walls. A smart facility can include manufacturing, logistics, distribution and power generation. The industrial spaces that use these devices can be tough environments, home to hazardous atmospheres, harsh chemicals and waste products. The expansion of technology into these locations demands increased protection for sensitive devices.
Designing for Reliability and Safety
Cable design plays an important role in ensuring safe and reliable operation.
A range of materials are used in the construction of copper cables for insulation and protection. Insulation is necessary to maintain separation of individual wires, both to keep different electrical circuits isolated and to prevent accidental contact with external equipment. This includes the safety of operators, especially when cables carry dangerous voltages.
These materials must provide mechanical strength, including the ability to withstand abrasion caused by constant movement. They must also offer the right resistance to any chemicals that might be present. The plastic and rubber materials used for the jacket of any cable must therefore be chosen with care to provide the right combination of flexibility, toughness and chemical resistance.
The choice of materials also plays an important role in safety, especially in enclosed spaces. Fire is one of the greatest hazards that designers face, and it is vital that cables do not create dangerous conditions if a fire does occur. That is why many cables are constructed with materials that are self-extinguishing to prevent the further spread of fire. Jacket materials can also be chosen that do not emit dangerous smoke or chemicals when exposed to flames.
Plenum cables are designed specifically for installation in buildings, where fire poses a particular hazard due to the dangers of harmful smoke spreading throughout the air. In Europe, cables designed to enhance the safety of users and the public use the acronym LSZH, which stands for low-smoke, zero halogen. For installers, LSZH cables deliver even greater safety due to their lower levels of hazardous gas they emit when exposed to flames. As a result, LSZH is also growing in popularity in the United States.
Preventing Interference
Copper cables need to be protected against the unseen dangers of electromagnetic radiation. The modern world depends on radio signals, with entertainment and communication systems using electromagnetic radiation to transmit data over long distances. Other emissions are unwanted, radiated from faulty equipment or long unprotected cables. This radiation is known as Radio Frequency Interference (RFI), sometimes known as Electromagnetic Interference (EMI).
The electromagnetic spectrum spans a wide range of frequencies from very low to very high. This radiation has a direct effect on the operation of electronic systems, as there is a close link between electricity and magnetism. It can interfere the transmission of data and signals along cables. In addition, cables carrying electricity create their own radiation which can affect the environment around them.
Electronic devices that work in this environment must resist electromagnetic interference, however it is created. Shielding is used to protect against unwanted radiation. Shielded cables use a combination of braided sleeves and foil layers underneath the jacket which is connected to ground , allowing the unwanted signals to be safely carried away.
The Right Cable and the Right Partner
Modern businesses must adapt to changing demands of their customers. The growing appetite for advanced technology will witness the need for systems that can perform far from the safety of the office or factory. Choosing a cable that can work reliably in demanding conditions is vital for today’s business user. Major Custom Cables boasts decades of experience, not only in the construction of bespoke cable assemblies but also in an unparalleled understanding of the tough environments that they face. When the conditions are tough, depend on MCC to deliver a cable that is up to the job.
