Braided Copper Ground Wire
Products Description
Braided copper ground wire is a grounding conductor made of multiple strands of high-purity oxygen-free copper wire (OFC) interwoven into a strip or rope structure using a specific braiding process. It possesses excellent conductivity, mechanical stability, and shock resistance. In environments with equipment vibration, high-frequency signal interference, and limited space, its performance is far superior to traditional solid copper conductors.
Three core characteristics of the product:
High flexibility: Can be bent and wound in confined wiring spaces without damaging the structure.
High conductivity: High-purity braided connectors ensure low impedance, low heat generation, and high transmission stability.
Safe and reliable: The braided structure evenly distributes mechanical stress, effectively reducing the risk of breakage.
Production Process: Safe Refining from Raw Materials to Finished Products
Raw Material Selection and Pre-treatment
Oxygen-free copper wire with a purity ≥99.95% (diameter...) is selected. (0.05-0.1mm) The conductor is degreased, pickled, and dried to remove surface oil and oxide layers, ensuring conductivity and braid adhesion.
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Precision Braiding
Braided to the designed density using a fully automatic braiding machine, the braiding angle and number of strands are controlled to ensure uniform conductor cross-sectional area, without looseness or broken wires. The braiding density error is ≤2%.
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Terminal Connection Processing
Copper terminals are crimped to the braided wire using an ultrasonic crimping machine. Pressure and time are precisely controlled to ensure connection strength and conductivity continuity. Some products can have terminals welded or anti-pull-out clips added as needed.
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Anti-corrosion Surface Treatment
Depending on the operating conditions, tin plating, silver plating, or insulation layer coating is applied. The tin plating process involves multiple steps: degreasing, pickling, tin plating, neutralisation, and drying, ensuring a uniform coating without peeling.
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Grounding Performance Testing
Grounding resistance is measured using a grounding resistance tester, and lightning current is simulated using a lightning strike tester to ensure the product meets design standards.
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Design Advantages: Co-creating with You, From Parameters to System
Scenario-Based Customised Design
We will accurately calculate and recommend the most suitable cross-sectional area, braiding density, and terminal type based on your application (such as the magnitude of the lightning current to be discharged, equipment vibration frequency, and electromagnetic environment level).
Diverse Terminal Options
We offer a variety of standard ring terminals, copper lugs, and flat terminals, and can also customise non-standard terminals according to your drawings to ensure a perfect match with your equipment.
Integrated Solutions
We can manufacture braided copper busbar customizables directly in conjunction with copper busbars, busbars, or other components, reducing connection points and improving the overall reliability and assembly efficiency of the system.
Engineering Considerations for Safety Margins
Our designs never settle for "just meeting the requirements," but rather reserve sufficient safety margins based on the importance of the application, ensuring that the grounding system remains foolproof even in the most extreme, unexpected situations.
Engineering Value: A Comprehensive Upgrade from Cost Savings to System Optimisation
Reduced Total Cost of Ownership
By improving the reliability of the grounding system, reducing maintenance frequency, and extending equipment life, the total cost of ownership is significantly reduced. In long-term applications, total costs can be reduced by more than 30%.
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Improved System Efficiency
Stable grounding connections reduce energy loss and improve the efficiency of the entire system. In high-current applications, energy loss can be reduced by 2-3% for Braided copper wire.
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Enhanced System Reliability
Reducing grounding faults improves the reliability of the entire system and prevents system downtime caused by grounding problems.
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Supporting Sustainability
Longer service life and lower maintenance requirements reduce resource consumption and support sustainability goals.
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