HOW ARE ELECTRICAL CABLES AND WIRES MADE?
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- Опубліковано 11 кві 2022
- 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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Leave a like if you want to see more videos like this! 👍
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Dude, you will be making more money from youtube soon than been an electrician
What I always find amazing about stuff like this, is not so much the product being made, but the machines that make it.
The thinking that must go into making the machines that make the machines.
Especially considering that many of these machines have been in operation unchanged for the last 50 years or so. Engineering made to last forever.
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!
Thanks for having us guys!
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.
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!
Great thanks for the feedback!
Great video, like you to do Hager.
Let’s visit Wiska HQ, then maybe a trip to Germany for the Wago factory 😄
@@damienheads7151 IF in Germany, then pop over the border to France & visit Hager's factory
Amazing video! As an electrician it’s an amazing view to see how the cables are actually made
📦
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.
I spent a week there as my industrial experience around 1969/1970. Fascinating place, and I remember the copper ingots well.
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.
Stuff Made in the UK is what I like to see, and use.
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.
Excellent video Jordan. Thrilled to see the industrial might of Doncaster is still producing leading edge technology.
It's always very interesting to see videos like this and they are always welcome. Thank you!
Amazing video, the style of content you creaate is always of top quality, entertaining and educational! I've just signed up to start my electrician course!!! Gotta start somewhere right!! Keep it up team!
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.
I would love to go see that. How did you get that opportunity
It's great place, very interesting.
When i was doing my apprenticeship at BT, some of the guys in my college course were from the factory, so we got to visit a couple of times. BT bought them when they were struggling in order to guarantee their cable supply then sold it on a few years later.
This is what makes me happy, this is what makes me feel satisfied! Great stuff mate!
How do you make copper wire? Hand a Scotsman 2p and try and grab it back. I am Scottish and I can confirm this ;-)
😂
Very interesting video thanks Jordan. Would love to see more how it's made videos. 😃
Great video, always interesting for people to see how things like this are made. When I was a manager at Openreach I used to be able to arrange tours around what was then the BT Cables factory in Manchester. It was always interesting to watch how the various sized cabled were made, from 2 pair 0.5mm drop wire to 4,800 pair 0.4mm main distribution cables with grease filled cables in the middle pairs wise (5 to 100 pairs).
It’s a great insight, and makes you think twice about everything knowing how it’s made!
Finally a non bullshit all science and learning channel. ❤ 👍👍👍
Keep up the good stuff.🙂
Excellent video, I love watching stuff like this, it is so interesting to watch. Great commentary👍😎
Thanks 👍
Amazing about copper. Great show video inside the building. Thumbs up!! Cheers!!
That was cool to see how copper wire is made love it 👍👍👍👍👍
I find all your videos entertaining and interesting to watch, this was no exception and nice to see something a bit different.
One idea for a video would be how a Power station works. Having worked at Drax (biggest power station in the UK) I can confirm it is a fascinating place to visit and I'm sure they would be open to some kind of tour. maybe leading onto a mini series, how PV cells work, Wind turbines etc.
Another suggestion would be how pump storage works as a kind of battery, (Cruachan power station for example) and how power storage is required as part of the solution to what will become an energy crisis.
Thanks for the suggestion Alan!
having your company name printed on the cable was really cool, i can see a market for that and potentially a requirement
Are you sure you want cable with your name on it after it’s been re-worked by DIYers and kitchen fitters?
great video, very interested in seeing behind the scenes of parts of the industry we don't normally get to see. I would be particularly interested in seeing how manufacturers test products to see if they meet british standards, like IP ratings etc. For example there was a controversy over how easy it was to pull wires out of the new MK screwless lever sockets, lots of sparks on instagram shown pulling them out and saying they wont use them, but surely the product was tested before manufacture to meet the requirement?
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.
Never really wondered how cable is made but it was interesting to see
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.
I know what you mean, we'll take note future vids
This place is 10mins drive away from me ... It is truly a wonder of British graft and dedication .... brilliant !
Interesting stuff, cheers for that 👍
Brilliant I enjoyed this film, some fantastic machinery in there.
It would be great to see how sockets and switches are made, a quality brand like Mk etc.
thank you, regards, Chris.
You're giving the Discovery Channel's How It's Made a run for its money!
I personally think copper may be my favorit color from the metals. Gold is close, and it may depend on my mood what I think is the best. But I love the light brown shiny surface
Great video. Very nice and interesting process.
It was fascinating
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
Really enjoyed that, very interesting.
Glad you liked it!
@@artisanelectrics next time I'm wrestling with a big SWA, I will appreciate what has gone in to making it .
Great British cable 👍
Interesting in watching how cables are made from raw stock. Thanks!!!
thanks jordan great stuff
I sitting at windsor railway station
there is a marvellous electric public toilet and cafe... its cable heaven..
Love this video...thank you for the tour!
Would l like to see how your (UK) transformers are made to compare how ours (US) are done.
Fascinating 👍
Interesting video Jordan - would love to see a tour of the MK factory in Basildon, Essex, if that ever becomes a possibility...
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.
Interesting !
Awesome stuff. I think you should have left the natural audio in though, it would've felt more like an authentic tour with natural factory sounds in
very cool
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.
I watch your videos, your information is useful,, I wish you success
Great to see made in uk
that was interesting Jorden
You can make a video about how and from what the varnish for insulating copper wires in rotors, stators and transformers is made, and how this varnish is applied and cured on copper wires. There is no such video on youtube, I think it should have a lot of views.
interesting video , Jordan
I used to work for CEF and used to collect cable from here!
Wow awesome video….
awesome
Very cool. Love to see power station to substation. Star Delta. Where the TN-CS TN-S earth's are etc.
more videos like this!
Wow Doncaster what a town
Great video and commentary. Has Jordan considered work as a voice over artist? He’s a natural - he should get himself an agent. There’s a series called “How It’s Made” - I’m not sure if they’ve covered manufacturing cables.
Cool!
what are the tests you perform before release?
What kind of tensile tester machine is it with extensometer or without?
Do you know anything about the specific type of cable that was being manufactured there and what that particular cable was intended to be used for?
Very Interesting. In my area, we had a company called BICC, (British Insulated Callender Cables), who had a few manufacturing plants. After acquisitions, mergers etc they closed the local factories with hundreds of job losses. They get just too big and want more profit to make it viable when there is a good market out there as Doncaster Cables has shown.
Brian, I’m in the process of renovating my house - when I removed all the old sockets and lightswitches to replace them last year, discovered they are all made by BICC. Hadn’t heard of them before, so it’s interesting to hear what that stands for. Cheers!
I served my apprenticeship at BICC BTCL, and once that smell of molten plastics from the extruders is in the memory bank, it can't be forgotten. Happy days!
4:37 looks like you could cook it up for supper!
His amazing
Do they perform flame propagation tests (IEC 60332 etc.) for every batch?
What home automation systems are you using, if any, in the UK? I’m using Pixie by SAL or Clipsal Wiser in Oz.
Hey love the videos
Why is my mouth watering
Hope the outside compound has good security with all that copper !!
There’s the wire stretcher! I knew those guys on the job were lying😂
I’m not an electrician but I still want my name printed on all the cables in my house! :)
😅 Bragging rights.
In the 70’s there used to be a factory on the outskirts of Doncaster that made wire and cables / slings for cranes I went in 1977 for training when I was an apprentice with British steel. This is not the same factory then ?
Best tools to buy etc that would be good
Free marketing. Smart company.
Another great video. You forgot Like, Subscribe and Notify at the end! Lol.
Cool video and the buyers of the copper must be pretty stressed as the LME prices are mental ....
Cleveland cable company next for the big stuff?
Video shows everything but the only processes that are genuinely interesting - how they get wires from molten copper and how exactly molten plastic harness is attached/melted on the wire without seams and still being smooth and keeping constant thickness through all the wire.
Move over Gregg Wallace (BBC Inside the factory)
Id be interested how much of the source copper used is virgin or recycled????
More tool videos please
Head over to our second channel we’ve got some great tool videos coming out soon - ua-cam.com/users/Tools4Sparks
i have a few friends who run cable companies, and they are so noisy. What's different is here in China, the copper is sold on the market as demands are needed, People will trade in copper and sit on stock of rolls of the stuff. Network cables yield better profits and orders are per specifications, it's a right minefield of abbreviations and qc standards. But very cool to watch.
Good to see factories in UK making such stuff. i wonder where the base copper is imported from?
Scrap man’s dream don’t you mean I would love to look in there skip to see how much copper they throw away
Can you do one on how beer is made? I’m sure it’ll be quite popular. 🙂
😂
How about dealing with stress? It's something I have had all throughout my 16 years in the industry.
Could make a very interesting topic thanks for the suggestion Gary.
Inside the pringles factory next plz 😋👍 with free sample for subscribers 🤣
😂😂😂
I am interested
The film Matrix was right. We are plugged in
👍
Nice! But how are electricians made?
Unicorn powder and 30,000 volts 😎
I saw cables being made in Stalybridge at Delta Enfield Cables in 1983. It's now a giant Tesco! It's fascinating. Thanks for the video.
Bats next ?
If you could make a video about how a transistor is made from complete scratch @artisanelectris
Was the way you said insulation like inshulation due to script being written that way or is it just the way you say it? :think:
College teachers: Don’t strip the T+E using the CPC, you’ll damage and stretch the copper.
Meanwhile at Doncaster cables…
Fire alarm test
How’s the your new electric van doing
Really great thanks, few videos coming soon with a little update. We’ll hopefully film a little episode with a follow up too it.