Air Cooled Round Stranded Cables
Products Description
Air Cooled Round Stranded Cables are made of high-purity circular copper wires bundled together in a multi-layered spiral stranding pattern. Stable operating temperature is achieved through natural heat dissipation from the external air, ensuring reliable performance even under high current, high power, and prolonged load conditions.
Its core highlights are:
The circular stranded structure provides greater flexibility and fatigue resistance.
Excellent air convection heat dissipation reduces heat accumulation.
Stable current transmission, suitable for high current density applications.
Resistant to bending, less prone to wire breakage, and extends connection life.
Suitable for various scenarios such as power connections, busbar replacement, flexible connections, and energy storage cables.
For engineering projects that prioritize stability, installation flexibility, and long lifespan, it is a safe and reliable preferred solution.
Technical Highlights: Innovations Hidden Behind "Air-Cooled Stranding"
1. Synergistic Heat Dissipation Through Air Cooling and Stranding
Spiral Groove Airflow Guidance: The groove design features an "involute shape," increasing airflow velocity by 20% from inlet to outlet, creating a "chimney effect" and enhancing convective heat dissipation. The stranding structure ensures a uniform braided connectors outer diameter, preventing localised airflow obstruction.
Fin-Stranding Coupling Design: Fins are only located in straight sections of the braided flexible busbar (non-bending sections), ensuring heat dissipation without increasing bending resistance, addressing the pain point of "finned cables being unable to dynamically route cables."
2. Micro-Innovations in Stranding Technology:
Unequal Diameter Single Wire Stranding: The outer layer single wire diameter is slightly larger than the inner layer (e.g., 0.2mm for the inner layer and 0.25mm for the outer layer), improving the outer layer's abrasion resistance (the single wire can still protect the interior after sheath wear), extending the cable's drag life.
Pre-twisted connectors: Both ends of the copper braided flexible connectors are pre-twisted into "soft connection sections" (100~200mm in length). This disperses stress during crimping with the connector, preventing single-wire breakage at the joint.
3. Intelligent monitoring features: Optional fibre optic temperature sensors (0.5mm in diameter) can be embedded in the air-cooling tank to monitor cable hotspots in real time (accuracy ±0.5℃). Data is uploaded to the maintenance platform via a wireless module, enabling "overheating early warning."
Technical Features and Key Functions: Transforming Design into Customer Value
Balance of High Current Carrying Capacity and Low Temperature Rise
Excellent conductivity and efficient heat dissipation structure enable it to have a higher safe current carrying capacity than traditional flexible braided copper busbars of the same cross-section, while maintaining a lower surface temperature under full load, improving system safety and energy efficiency.
Extra-Long Bending and Vibration Life
Having undergone rigorous bending fatigue and vibration testing, our flexible braided busbars can withstand dynamic stresses far exceeding industry standards, making them particularly suitable for applications requiring frequent movement or prolonged exposure to vibration, significantly reducing replacement frequency.
Quick Installation and Maintenance
The flexible structure makes wiring in confined spaces easier, allowing for bending and shaping. We also offer pre-fabricated connectors (cold-pressed or tin-plated) to simplify on-site installation, improve construction efficiency, and enhance connection reliability.
Application Advantages: Multi-Scenario Solutions
High-Temperature Industrial Environments
In high-temperature workshops such as metallurgy and chemical plants, ordinary cables often overheat and fail due to high ambient temperatures. Our insulated flexible copper bars can operate stably in environments above 60℃ and have been successfully applied to the blast furnace control systems of multiple steel plants, ensuring the continuous operation of critical equipment.
Dense Cabling Spaces
In space-constrained scenarios such as data centres and server racks, the temperature rise problem caused by poor heat dissipation of traditional cables is particularly prominent. The natural heat dissipation characteristics of braided copper ground wires make them an ideal choice for high-density cabling. They have been deployed in multiple hyperscale data centres, supporting improvements in system energy efficiency ratios.
Electric Vehicle Production Lines
In automated assembly lines, cables often overheat due to frequent movement. The flexible design and efficient heat dissipation capabilities of braided copper wires make them the first choice for automobile manufacturing production lines, successfully solving the problem of production line downtime caused by cable overheating.
Renewable Energy Systems
In inverter connections in photovoltaic power plants and wind farms, ambient temperature variations are large, and heat dissipation conditions are poor. The adaptive heat dissipation capabilities of copper stranded wires ensure the stability of power transmission and have been applied in multiple offshore wind power projects, significantly improving system reliability.
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