Professional Development

WIREE JOU JOURNAL MAY 2017

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50 RS YEA 8-2017 196

INTERNATIONAL www.wirenet.org

OFFICIAL PUBLICATION OF THE WIRE ASSOCIATION INTERNATIONAL

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Next issue June 2017 • Testing & Measuring • Interwire 2017 Wrap-Up

Gen Z an d Millen nials Want to Work in ® a Collabor ative Em pi Where In re -Person Communic ation Is Ki ng ONAL

WIRE JOURNAL MAY 2017

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Professional Development . . . . 34

A WAI reintroduction . . . . . . . . 48

TECHNICAL PAPERS

Cover: A group photo of participants in the post graduate program of the Prysmian Group Academy’s School of Management at the company’s training center.

Photo courtesy of Prysmian.

MAY 2017 | 3

CONTENTS

INSIDE THIS ISSUE Georgetown steel: the sequel3

10

Could this have the makings for a reality TV show?

If one could personify the saga of Georgetown Steel— twice reopened and shut down—this could be it, as the wire rod operation in Georgetown, South Carolina appears poised to have a third go of it. ArcelorMittal has agreed to sell the business to U.K.-based Liberty House Group, which wants to establish a presence in the U.S. The local steel union is ready to embrace the restored jobs, but some town officials still want to go ahead with a zoning change that would prevent this from ever happening a fourth time.

4 | WIRE JOURNAL INTERNATIONAL

Got steel questions? We’ve got 1,162 pages of answers for you

48

Published in 2008, WAI’s Ferrous Wire Handbook, remains the most comprehensive single source of information source about steel and steel alloy wire production. The WAI is reintroducing this ultimate steel industry resource, with the first chapter presented here, along with the Table of Contents.

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The complete program is available at The complete program is available at www.henrich.net www.henrich.net HENRICH designs, manufactures, supplies and HENRICH designs, manufactures, supplies and installs custom-made and on demand. installs custom-made and on demand.

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EDITORIAL EDITORIAL

Shop floors will continue to change ... and that’s not necessarily a bad thing The feature in this issue, professional development, covers a range of topics, but one area that was not directly focused on was the amount of manufacturing jobs in general that have disappeared due to advances in technology. The irony is that employees today—courtesy of advances in equipment and R&D—can produce far more than their counterparts a generation ago, but there still is a shortage of new and key employees, one likely to worsen as more industry veterans retire.

A recent White Paper from the Association for Advancing Automation (AAA), “Work in the Automation Age: Sustainable Careers Today And Into The Future,” notes that 80% of manufacturers report a shortage of qualified applicants for skilled production positions. “Studies show an increasing skills gap with as many as two million jobs going unfilled in the manufacturing industry alone in the next decade.” Manufacturing jobs pay better than other non-farm industries, but it still can be difficult to hire new staffers: the average is 94 days to recruit engineering and research employees and 70 days to recruit skilled production workers.

The AAA says that companies must adapt to the automation age. They will need to fill new positions that never existed before, from computer vision and machine algorithm designers and industrial network integration engineers to IoT/data analysts and material movement controls engineers.

The end result, eventually, will be that shop floors will have even more talented people...if the industry can attract them, which as discussed in the feature, may well be the biggest challenge.

An industry classic returns As this issue features a focus on personnel, it is appropriate that WAI is reintroducing its Ferrous Wire Handbook. At 1,168 pages (34 chapters), it offers a comprehensive wealth of information about steel and steel alloy wire production that remains both valid and enlightening, presenting different technology, product sectors types, useful process theory and more. See p. 48.

Mark Marselli Editor-in-chief

6 | WIRE JOURNAL INTERNATIONAL

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CALENDAR

CALENDAR June 5-8, 2017: wire Russia Moscow, Russia. To be held at the EXPOCENTRE in Krasnaya Presnya, this event is organized by Messe Düsseldorf. Contact: Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com.

June 9-11, 2017: Wire & Cable Guangzhou 2017 Guangzhou, China. To be held at the China Import Export Fair Complex. Contact: Guangzhou Guangya Messe Frankfurt Co., tel. 86-20-38251558, wire@china.messefrankfurt.com, www.wire-cable-china.com.

Sept. 19-21, 2017: wire Southeast Asia 2017 Bangkok, Thailand. To be held at the Bangkok International Trade & Exhibition Centre (BITEC), it is organized by Messe Düsseldorf. Contact: Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com.

Oct. 8-11, 2017: 66th IWCS International Cable & Connectivity Symposium Orlando, Florida, USA. Contact: Pat Hudak, IWCS, tel. 717-993-9500, phudak@iwcs.org, www.iwcs.org.

Nov. 7, 2017: CabWire World Conference 2017 Düsseldorf, Germany. To be held at the Congress Center, this event is organized by U.K.-based IWMA. Contact: IWMA, tel. 44-121-781-7367, info@iwma.org, www.iwma.org.

May 15-16, 2018: WAI Operations Summit & Wire Expo 2018 Nashville, Tennessee, USA. This WAI event, to be held at the Gaylord Opryland Resort & Convention Center, includes the Association’s trade show, technical programs and 88th Annual Convention, www.wirenet.org.

Oct. 3-5, 2017: Wire South America São Paulo, Brazil. To be held at the Imigrantes Exhibition & Convention Center. Contact: Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com.

WIRE ASSOCIATION INTERNATIONAL EVENTS June 16, 2017: Midwest Chapter 15th Annual Golf Tournament West Chicago, Illinois, USA. To be held at St. Andrews Golf & Country Club. Contact: Steve Fetteroll, tel. 203-453-2777, ext.

115, sfetteroll@wirenet.org.

September 12, 2017: New England Chapter 23rd Annual Golf Tournament Avon, Connecticut. To be held at the Golf Club of Avon. Contact:

8 | WIRE JOURNAL INTERNATIONAL

Steve Fetteroll, tel.

203-453-2777, ext. 115, sfetteroll@wirenet.org.

September 21, Southeast Chapter 16th Annual Golf Tournament Conover, North Carolina, USA. To be held at the Rock Barn Golf and Spa, Conover, North Carolina.

Contact Steve Fetteroll, tel.

203-453-2777, ext. 115, sfetteroll@wirenet.org.

May 15-16, 2018: WAI Operations Summit & Wire Expo 2018 Nashville, Tennessee, USA. This WAI event, to be held at the Gaylord Opryland Resort & Convention Center, includes the Association’s trade show, technical programs and 88th Annual Convention.

INDUSTRY NEWS

INDUSTRY NEWS ArcelorMittal agrees to sell Georgetown Steel, U.K. owner wants U.S. presence

Commerce Department investigating steel wire rod dumping/subsidizing ...

Georgetown Steelworks, a storied business that has seen highs and lows since the wire rod operation was founded in 1969 in Georgetown, South Carolina, appears—once again—to have found new life.

A press release said that U.K.-based Liberty House Group has agreed to buy the Georgetown Steelworks plant from ArcelorMittal, which closed the operation in 2015. The selling price was not disclosed, and at this point there was no proposed timetable for operations to re-start, assuming the deal is finalized and a workforce established. The plant, which has wire rod operations with capacity of some 680,000 metric tons a year, also has an electric arc furnace.

The U.S. Department of Commerce (DoC) is investigating whether imported carbon and alloy steel wire rod from manufacturers in 10 countries are dumping product, and whether two others have been subsidized.

DoC reports that the probe affects imports from Belarus, Italy, South Korea, Russia, South Africa, Spain, Turkey, Ukraine, the United Arab Emirates and Britain; the subsidization probe covers those from Italy and Turkey.

The action follows petitions from Gerdau Ameristeel US Inc., a subsidiary of Gerdau SA, Nucor Corp., Keystone Consolidated Industries and Charter Steel, it said.

Per DoC, in 2016, the estimated imports of carbon and alloy steel wire rod were valued at an estimated $10.4 million from Belarus; $12.2 million from Italy; $45.6 million from South Korea; $32.3 million from Russia; $7.1 million from South Africa; $40.7 million from Spain; $41.4 million from Turkey; $55 million from Ukraine; $7 million from the United Arab Emirates; and $20.5 million from the United Kingdom.

If the U.S. International Trade Commission makes a preliminary finding by a May 12 deadline that the imports cause damage to U.S. producers, the investigations will continue, DoC said.

Third time the charm? Georgetown Steel, twice before closed and re-opened, may get a third chance.

“Our agreement in principle with ArcelorMittal opens the door to the eventual restoration of several hundred jobs, both directly and in the supply chain, and it gives this region’s economy a new industrial focus,” Sanjeev Gupta, the executive chairman of Liberty, said in a statement. “Acquiring the plant at Georgetown, with its ability to recycle scrap steel in an arc furnace, gives us a strong platform from which to launch our strategy in the USA.” The agreement marks the “first significant step in Liberty’s plan to make major investments in the U.S. steel industry,” the statement said.

James Sanderson, the president of United Steel Workers Local 7898 union, was cited in a local paper, The Sun News, as saying that he expects 300 to 350 jobs could come back to the mill. However, that same report cited some reluctance by city officials who were planning to rezone the area. “Hopefully they will be successful where these other companies have not been,” Mayor Jack Scoville said. “If not, we’ll have the zoning in place and we’ll be able to transition to some other use if it does shut down again.”

... but AWPA members tell ITC that they oppose import duties on wire rod Five members of the American Wire Producers Association (AWPA), speaking at a preliminary hearing of the U.S. International Trade Commission on Tuesday, April 18, adamantly opposed proposed import duties being imposed on imported wire rod, declaring that they would cause major problems to the U.S. industry.

Per a report at the AWPA website, explanations were presented to the ITC by five companies that annually buy more than a million tons of wire rod. Those speakers —John T. Johnson, Mid-South Wire; Christian Stauffer, Insteel Industries; Bob Moffitt, Heico Wire Group; Terry Hughes, Bekaert Corporation; and David Minnick, Kiswire—testified on behalf of AWPA. There were also company witnesses from POSCO. The presentations went into detail explaining the effect of what could happen if the sought relief was granted.

Also speaking against the proposed actions was AWPA Executive Directory Kimberly Korbel. She noted that AWPA members—whose member companies include the petitioners—overwhelmingly voted against the requested actions. WJI will have more on this in its June issue.

Got news? E-mail it to the WJI at editor@wirenet.org.

10 | WIRE JOURNAL INTERNATIONAL

This is a hot story about an ambitious long-term project, but if it works out, a volcanic energy source in Iceland could lead to record results for the renewables field, while also powering the need for a very sizable cable order.

A Krafia geothermal power plant in Reykjahlid, Iceland.

Reuters photo/Lefteris Karagiannopoulos.

Per a report by Reuters, the project is being coordinated

by Iceland’s Geothermal Research Group and the British Geological Survey, with the participation of 38 institutes and companies from 11 countries, including the United States, Canada and Russia. Producing geothermal energy

Wire & cable in the news Could billionaires be key to making the U.S. electricity superhighway a reality?

There seems little doubt that the collective U.S. power grid needs major improvements, but to date investments in it have lagged considerably, all of which has led to a new trend: a push by individuals with deep pockets. In other words, billionaires.

An April 7 story by Russell Gold in The Wall Street Journal outlined one such project. It reported that crews in rural Wyoming are prepping land near the state line with Colorado so they can build a 3,000-megawatt wind farm that could be the largest one ever constructed in the U.S. One key to moving the renewable power to market is billionaire Philip Anschutz, who owns the 500-sq mile ranch, and wants to build a 730-mile transmission line to deliver the electricity to a point near Las Vegas. From there, the power can flow to southern California’s grid.

Despite deep pockets and state mandates for more renewable energy, fortifying the grid to move green power from the middle of the country—where it is reliable and cheap to produce—to metroplexes where the power is needed has proved problematic, said Bill Miller, who is heading the Anschutz Corp. project. Other investors and financial partners may join the effort.

“Being somewhat naïve at the time, I thought that even a project as complex as this could have been done in five

Do you have an industry hotshot?

A slew of “30 under 30” profiles of up-and-coming newcomers to a given field have become very popular in recent years. The WAI’s Board of Directors believes that such recognition should extend to professionals in the wire and cable industry. With that mindset, the WAI is issuing a call for Industry Hotshots.

If you have someone in your ranks, under age 40, whose smarts and work ethic make that person a star in your ranks, we encourage you to nominate that person. If selected, the person will be profiled in the September issue of WJI. For details on the process, either call WAI Executive Director Steve Fetteroll at tel. 203-453-2777, ext. 115, or send him an e-mail at sfetteroll@wirenet.org.

from magma would enable Iceland to export more energy and could also revive a plan to build a power cable from Iceland to Britain to provide power to British homes, in what would be the world’s longest power interconnector.

In 2016, Iceland agreed with Britain to study building the 1,000-km long IceLink cable, which could power 1.6 million British homes from the island country’s vast

years,” Miller said. Converting the cattle ranch to a wind farm is not a big deal. “I just look at it as energy, pure and simple. A wind turbine is just an oil well turned upside down.”

Nearly nine years later, the project is still being developed. Bill Miller at the proposed wind farm site.

The multistate transmission line did get a key federal permit, and Miller now expects Wyoming wind power to flow into southern California by 2021.

The article said that Anschutz isn’t the only wealthy investor willing to back major power-line projects.

The Ziff family, whose fortune harks back to the glory days of magazine publishing, also is partly funding a green-power project between Oklahoma and Tennessee.

Altogether, these and other merchant-transmission projects could cost upward of $17 billion, plus at least another $20 billion in wind, solar and hydro projects to fill these lines.

MAY 2017 | 11

INDUSTRY NEWS

Geothermal project in Iceland could lead to 1,000-km power cable order

INDUSTRY NEWS

geothermal resources. The project, which was described as being a first for obtaining thermal energy from magma, is estimated to cost $100 million. If successful, it could produce up to 10 times more energy than from a conventional well.

Per the Reuters report, those plans had been moving forward but were delayed due to Britain’s “Brexit” vote to leave the European Union. There was also concern in Iceland that exports would increase power prices at home and reduce the island’s attractiveness to energy-intensive industries such as data centers.

“Verizon’s purchase commitment supports necessary capacity investments across our manufacturing footprint,” said Corning Executive President Clark Kinlin. The expansion project is expected to be completed in 2018.

JDR to supply 155 km of cable for windfarm off U.K.’s Suffolk coast U.K.-based JDR reports that it has been chosen to supply 155 km of array cables for an offshore wind farm project.

Corning to supply Verizon as much as 20 million km of fiber optic cable Corning and Verizon agreed to a three-year deal that calls for the supply of up to 20 million km of optical fiber cable and associated hardware from 2018 to 2020.

An announcement said that Verizon will use the Corning fiber to boost critical coverage and capacity for its nationwide broadband network as it reinvents its network architecture to support 4G, and in preparation for 5G. The cable will further Verizon’s plans to deliver high-speed broadband to homes and businesses across the U.S. A report in capacitymedia.com described the overall deal as being worth a minimum of $1.05 billion. Part of the fiber deployment is related to One Fiber, which Verizon launched in Boston last year. The carrier has committed to a $300 million investment in fiber across the city over the next six years.

In related news, the report said that Verizon hired former Ericsson CEO Hans Vestberg to oversee its fiber network business as part of a wider restructure of the business. It also recently closed the $1.8 billion acquisition of XO Communications, giving Verizon metro fiber rings in 45 of the top U.S. metro markets.

“Our plans identified a shortfall in fiber supply, and Verizon has been working with business teams to forecast demand and fill supply gaps with existing suppliers,” said Viju Menon, Verizon’s chief supply chain officer.

“Securing the required volume of optical fibre and hardware solutions with Corning will ensure we meet our planned rollout schedules.”

Earlier this year, Corning reported plans to invest $176 million in its Corning Optical Communications subsiduary’s facilities in Catawba and Cabarrus in North Carolina, creating 410 jobs over the next two years. The company will invest $67 million in a new optical cable manufacturing plant in Newton and $109 million to expand its existing optical fiber plant in Midland.

Corning has pledged to invest a total of some $250 million in its optical fiber, cable and solutions manufacturing division to meet growing carrier demand for fiber.

12 | WIRE JOURNAL INTERNATIONAL

JDR’s will supply 155 km of array cables to VMBS. A press release said that JDR was selected by VBMS, which has a contract from ScottishPower Renewables to supply, install, bury, terminate and test the 102 66kV cables. They will be used for the 714 MW East Anglia 1 offshore wind farm that is off the U.K.’s Suffolk coast.

JDR will design and manufacture the array cables, including end terminations, as well as a cable management system at each turbine that allows for a 66 kV topside connection to the switchgear.

The cables are to be made at the company’s Hartlepool facility for delivery in the first quarter of 2019.

Prysmian expands its capacity for manufacturing offshore cables The Prysmian Group announced that its U.K. production facility in Wrexham can now manufacture both 33 kV and 66 kV submarine cable cores used for the interarray cable connections in offshore wind farms.

A press release said that the new product line will enable the linking and collecting of power produced by offshore wind turbines before onward transmission to the onshore grid. The company notes that it is the largest manufacturer of cable and accessories in the U.K., operating multiple factories as well as extensive cable installation and test services across England, Scotland, Wales, Northern Ireland and beyond. Its high-voltage facility in Wrexham is the only factory in the U.K. that is capable of manufacturing submarine cable cores.

Fort Wayne magnet wire manufacturer plans to move this year to larger site Alconex, a Fort Wayne magnet wire manufacturer that is planning to build a new $7 million plant in the same Indiana city, expects that the company will create 25 jobs within five years.

An on-line report in the News-Sentinel said that Alconex, which currently operates an 80,000-sq-ft facility at 4204 W. Ferguson Road, plans to build a 100,000sq-ft plant at Cook and Chalfant roads that could be expanded by another 50,000 sq ft if necessary.

President and CEO C. David McBane was cited in the report as telling the city’s Redevelopment Commission that he wants the company to stay in the city, but that he needs more space. The company has about 60 production and 11 office workers, and it is not possible to expand the existing structure, making the move a necessity.

“We’re in our 30th year in Fort Wayne, which has a rich history in the industry,” McBane said. “Seventy percent of our products go to Mexico, and (fellow wire makers) Rea and Essex have yielded to that tug. Magnet wire in Fort Wayne is 5% of what it used to be.”

Construction is expected to begin this year, and the move will be completed in stages over several months in order to maintain production, the report said.

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INDUSTRY NEWS

“Our Wrexham factory has been manufacturing the highest quality cables for decades and we are delighted to be directing this depth of experience and know-how to products that will further grow the business, sustain and create local jobs and provide U.K. manufactured cables for the next generation of U.K. and European offshore wind farms,” said Prysmian UK CEO Llyr Roberts.

In the U.K., Prysmian already has an established and strong presence serving the offshore wind energy sector.

Alongside a dedicated submarine operations and engineering office in Chelmsford, Prysmian operates an offshore logistics and services base in Middlesbrough, which serves as a center of excellence offering maintenance, repair and cable storage services for all offshore cabling.

It is also in Middlesbrough where the cable laying vessel, Cable Enterprise, is based, as well as cable burial and protection equipment that supports Prysmian’s ability to execute submarine cable projects.

INDUSTRY NEWS

AMSC to cut staff, considers move to smaller site to reduce operating costs

Nexans to supply cable for major Norway offshore wind project

AMSC, a U.S. global solutions provider serving wind and grid leaders based in Devens, Massachusetts, announced that it is “exploring options” to move to a smaller building as part of overall expense cutting that includes a workforce reduction.

Nexans reports that one of its subsidiaries has been chosen to supply cables for the Roan Wind Farm, the first of six windfarms in Fosen Vind DA’s development in Central Norway.

A press release said that Linka AS, the electrotechnical contractor for the project, chose Nexans to supply the cables for Roan Wind Farm. The Nexans subsidiary will supply 200 km of TSLF 36 kV underground cables to interlink the turbines and transmit the power to the grid.

Delivery has already started and will run through March 2018, shortly before the scheduled completion of the first leg of the overall project, it said.

“We have enjoyed many years of fruitful cooperation with Nexans on other projects, both large and small, and they have been dependable in all project phases, from tendering and sales processes, logistics planning, right through to the safe transport of cable onto site,” said Knut Arne Aasan, CEO of Linka AS. The first Roan Wind Farm will have 71 turbines and capacity of 255 MW, the release said. The construction contract was awarded to Johs. J. Syltern AS, whose tasks will include trenching and cable-laying.

AMSC wants to move from its current location.

A press release from AMSC said that the company is considering moving from its current location to a nearby, smaller-scale building. “Our company was founded 30 years ago with the purpose of manufacturing superconductor wire. Over the past several years, we’ve worked to diversify our product portfolio and transition the company to become the systems provider we are today,” said AMSC President and Chief Executive Officer Daniel P. McGahn. “We’ve evolved from manufacturing 1G superconductor wire to delivering full systems with our 2G wire process. We are delivering sustainable systems for the U.S. Navy fleet, grid infrastructure and wind turbine generators. As a result, our 16-year-old manufacturing facility is no longer suitable or sized for our current or near-term business needs.”

Per a report in the Telegram, the layoffs would be about 8% of staff. About a year ago, AMSC had some 400 employees.

AMSC expects to reduce its annualized expenses by approximately $4 million to $5 million once the savings are fully realized, which is expected to occur by the end of fiscal year 2017. It plans to reduce operating costs and align the organization for anticipated grid segment growth. AMSC intends to focus on optimizing the manufacturing capacity requirements of the company, as well as aligning its headcount to effectively support targeted revenue growth.

In other news, a filing with the Securities and Exchange Commission noted that CFO David A. Henry has resigned, replaced by John W. Kosiba Jr., the company’s senior vice president of Gridtec solutions and finance operations.

14 | WIRE JOURNAL INTERNATIONAL

Nexans has won an order to supply cables for the 255MW Roan wind farm in Norway.

The six wind farms will have a total of 278 turbines and capacity of 1000 MW, enough energy to meet the needs of 170,000 Norwegian households.

The project is expected to be completed in 2020, more than doubling Norway’s wind energy generation capacity. When completed, it will be Europe’s largest onshore wind power project, the release said.

Statkraft, Norway’s state-owned renewable energy producer, will hold a controlling 52.1% share of Fosen Vind DA. The other two owners of Fosen Vind DA are the power company TrønderEnergi and the European investment consortium Nordic Wind Power DA.

Gerdau SA has agreed to create a long-steel joint venture in Colombia with Putney Capital Management, creating a joint venture with the asset management firm, which is already its partner in the Dominican Republic.

Per securities filings, the company will sell half of its stake in a Colombian mill, Gerdau Diaco, to Putney. The venture is valued at $165 million. The product range includes annealed wire and wire rod.

“The new company’s assets are formed by Gerdau’s long-steel industrial units in Colombia, which have combined annual installed steel production capacity of 674,000 tonnes,” said a company statement from Harley Lorentz Scardoelli, executive vice president and investor relations officer. “The transaction is aligned with the process to optimize (our) asset base with a focus on profitability and deleveraging.”

volume for both diameter and height is 4,000 mm: large dimensions allow each base to load stacks of up to seven coils, ensuring the highest production flexibility and charge configuration.

The capacity is designed mainly for spheroidizing annealing of coiled rod (1,250 to 1,400 mm) and wire (4.5

SEARCHING FOR THAT The Gerdau website provides the following description. “Diaco is the main iron and steel industry in Colombia. It has the country’s largest scrap iron recycling plant located in the town of Tocancipá, where long-carbon steels are obtained. Additionally, the company has production plants in the Muña, Cali, Tutaand Duitama areas, as well as plants serving constructors in the municipalities of Cota, Cartagena, Bucaramanga, Pereira, Medellín, Yumbo (Cauca Valley),Tocancipá, and Duitama.

Diaco became part of Gerdau in 2004.

Danieli to supply annealing plant to Turkish company Danieli reports that the company has received an order to supply Danieli Olivotto Ferré annealing technology for processing wire rod coils to Turkey’s Diler Iron and Steel Industry and Trade Inc. A press release said that the order, received via Danieli Centro Combustion, will be installed in a dedicated area of the workshop in Dilovası, Kocaeli (Turkey).

Per Danieli, the project scope, designed for processing coils under a protective nitrogen protective atmosphere, will consist of three bases designed for a maximum workload capacity of 40 tons, plus two bell furnaces and a cooling hood. The useful workspace

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INDUSTRY NEWS

Gerdau to sell half of Gerdau Diaco in Colombia to investment company

INDUSTRY NEWS

to 27 mm), and can accommodate charges stacked up to 1,900 mm high.

Diler Iron and Steel Industry and Trade Inc., a business of Diler Holding, specializes in manufacturing wire rod coils for automotive applications.

Spain and Brazil announce plans for a 9,200-km subsea cable by 2019 Representatives for Spain and Brazil reported a plan to lay an undersea cable in the Atlantic Ocean to connect the two countries by 2019, underscoring efforts to route communications outside North America.

A Reuters report said that the announcement by Spanish Prime Minister Mariano Rajoy and Brazil Science, Technology, Innovation and Communications Minister Gilberto Kassab outlined the scope of the proposed EllaLink subsea cable. The optical fiber cable, designed for 72 Tbytes-per-second capacity, will connect data centers in Madrid and São Paulo, as well as in Lisbon, using shielded fiber rings. The cable will also connect the archipelagos of Madeira, Spain’s Canary Islands and Africa’s Cape Verde, they added.

At the announcement made in São Paulo, Rajoy said that the venture represents the first subsea fiber optic cable linking Europe to Brazil. A driver for the project

was that it would also improve data security and privacy by routing calls and Internet navigation outside the reach of the U.S. The idea gained traction almost four years after former Brazilian President Dilma Rousseff and other officials were alleged to have been the target of personal and economic espionage by U.S. intelligence agencies.

The only existing direct link between Europe and South America is a 20-Gb copper cable laid in 1999 by a consortium of voice operators.

Qatar okays deals for latest phase of mammoth power transmission project The Qatar General Electricity and Water Corporation (Kahramaa) recently signed multiple power transmission contracts with local and international companies, including four cable manufacturers.

Per a report from Qatar News Agency, the contracts that were bid out were part of Phase 13 of the Qatar Power Transmission System Expansion Plan. The project calls for the laying of 453.3 km of cable. That includes 36 km of 400 kV cables, 47.4 km of 220 kV cables, 285.8 km of 132 kV cables and 84 km of 66 kV cables. The suppliers for the transmission cables include LS Cable & System (South Korea), Larsen & Toubro (India), Furukawa (Japan) and Elsewedy Cables (Qatar & Egypt).

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Officials of Kahramaa and project suppliers at a signing ceremony for the mammoth power expansion project.

The collective projects include the laying of high-voltage cables at major infrastructure-oriented projects across the capital city and suburbs as well as 77 substations that will be constructed in various locations of the country. Attending the signing ceremony was Minister of Energy and Industry Dr. Mohammed bin Saleh al Sada.

The schedule calls for implementation of the different projects to be completed in a range of 16 to 26 months, the release said.

AIM and T. Butler Engineering enter a strategic alliance U.S.-based Automated Industrial Machinery, Inc. (AIM) and Ireland’s T. Butler Engineering Ltd. (TBE) announced that they have entered a strategic alliance.

A press release said that the alliance will combine AIM’s smart CNC machines with TBE’s high-volume production and customized turnkey solutions to offer “a truly unique proposition to prospective customers across the globe.” The deal will enable the suppliers of high-speed wire component manufacturing machines to also deliver a complete customer service solution, from highly technological software support to an integrated, intelligent and fast production experience. Further, starting in the second quarter of 2017, both companies will offer each other’s solutions, with AIM also providing support for TBE customers in North and South America, it said.

“Nothing is more important than making our customers more productive,” said AIM President Constantine Grapsas. “We are thrilled to announce this strategic alliance with TBE, which will simplify the customer experience across sales, service and support and empower our mutual customers to be far more productive.”

Observed TBE Managing Director Thomas Butler, “We believe that we can combine TBE’s niche capability for complex and integrated projects with AIM’s smart bending solutions and vast presence in the U.S., together offering an unparalleled level of manufacturing capability and flexibility to our mutual customers, serving the market together on a truly innovative platform.”

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INDUSTRY NEWS

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PATENTS

Patent REPORT Technical advances are a necessity for any industry, and to that end, companies invest considerable resources in R&D. This monthly section will list the abstracts of recently approved U.S. patents. Most are direct to wire and cable while a few may be more indirect/downstream.

Electric wire with connector and method for manufacturing the same U.S. Patent No.: 9,634,450 Patent date: April 25, 2017 Filed: Juy 7, 2016 Assignee: Yazaki Corporation, Japan Inventor: Junki Sugino An electric wire with connector includes: an electric wire; a connector having a housing chamber to house an electric terminal provided at an end of the electric wire, the housing chamber opening on an end surface of the connector; and a waterproof member to cover the housing chamber. The waterproof member includes a sheet member having a width extending from the end surface of the connector as a reference position toward both of the connector and the electric wire. The sheet member has a wrapping shape winding around in a manner to have an overlapped region of the front surface of one end of the sheet member and a back surface of the other end of the sheet member.

The front surface and the back surface are contacted each other at the overlapped region. An inner peripheral surface of an end part of the waterproof member near the connector is contacted to an outer peripheral surface of the connector, and at least part of an inner peripheral surface of the other end part of the waterproof member near the electric wire is contacted to an outer peripheral surface of the electric wire.

Waterproofing structure for insulation-coated electrical wire, and wire harness U.S. Patent No.: 9,633,759 Patent date: April 25, 2017 Filed: March 16, 2015 Assignee: Sumitomo Wiring Systems, Ltd., Japan Inventors: Masataka Wakabayashi, Hiroyuki Ootsuki, Kazuto Hasegawa The present invention relates to a waterproofing structure for an insulation-coated electrical wire that includes a tubular protection member and a resin material that is accommodated in the protection member. An exposed conductor section includes a plurality of bare wires bent to double back in a reverse direction in the protection member, the protection member including a tubular section that surrounds the exposed conductor section and the pair of on intermediate ends of the coating tube that are adjacent to both ends of the exposed conductor section; and a closed

18 | WIRE JOURNAL INTERNATIONAL

section that is distanced from the exposed conductor section in the axial direction and closes one end of the tubular section. The resin material is made of a thermosetting resin that is cured, between the protection member and the insulation-coated electrical wire, while closely fitting to the closed section, the exposed conductor section, and the pair of intermediate ends.

Wire harness and wire harness manufacturing method U.S. Patent No.: 9,633,757 Patent date: April 25, 2017 Filed: Dec. 3, 2015 Assignee: Sumitomo Wiring Systems, Ltd., Japan Inventors: Masataka Wakabayashi, Hiroyuki Ootsuki A wire harness having a portion of an electrical line group configured to easily housed in a protector without requiring the task of opening an overlapping portion of the protector, and a method for manufacturing said wire harness are provided. The protector includes a shape-memory panel having a shape-memory polymer sheet and noise suppression metal coating films formed on two surfaces thereof and are electrically conductive with each other. The shape-memory polymer sheet is molded in a shape-memory state for covering a portion of the electrical line group in a scroll-like manner, and then opened into a flat plate shape. The portion of the electrical line group is placed on the flat plate-shaped shape-memory panel, and then heated so that the shape-memory panel returns to the shape-memory state and covers the portion of the electrical line group in a scroll-like manner.

Apparatus and method for detecting cable fault U.S. Patent No.: 9,632,130 Patent date: April 25, 2017 Filed: Feb. 10, 2015 Assignee: Innowireless Co., Ltd. South Korea Inventors: Jin Soup Joung, Sung Chan Choi, Yong Hoon Lim, Kyoung Hwan Ju, Hyo Bin Yim An apparatus and method for detecting a cable fault which simultaneously apply a plurality of measurement frequencies mutually orthogonal to a cable and estimate reflection coefficients at the measurement frequencies using filters for filtering only the respective measurement frequencies to reduce a time taken to detect a cable fault.

Poly (arylene ether) flame retardant resin composition and non-crosslinked flame retardant cable U.S. Patent No.: 9,632,091 Patent date: April 25, 2017 Filed: Dec. 10, 2014 Assignee: LG Chem, Ltd., South Korea Inventors: Sung Hwan Lim, Nam Jib Park, Sang Ho Lee, Soo Min Lee, Jong Kuk Choi, Sang Wook Nar Disclosed are a flame retardant poly(arylene ether) resin composition and a flame retardant non-crosslinked cable.

According to the present invention, provided are a flame retardant poly(arylene ether) resin composition to provide flexibility, flame retardancy, productivity, extrusion processability, etc. while maintaining heat resistance, and a flame retardant non-crosslinked cable manufactured using the composition.

Illuminable transmission cable U.S. Patent No.: 9,628,898 Patent date: April 18, 2017 Filed: May 1, 2015

Assignee: Molex, LLC, USA Inventors: Ting Chang Tseng, Yao Ting Wang A cable connector comprises a mating board, a plurality of cables, an organizer and a binding material. The mating board comprises a board body and a plurality of conductive portions provided on the board body. The cables are respectively electrically connected to the conductive portions. The organizer comprises an upper cap, a lower cap and a spacer interposed between the upper cap and the lower cap. The upper cap, the lower cap and the spacer cooperatively define a filling space that includes upper cable passages and lower cable passages respectively extending along the front-rear direction and respectively receiving the cables so as to allow the plurality of cables to pass through the filling space. The binding material is filled in the filling space of the organizer and fixes the plurality of cables to the organizer.

Crosslinkable halogen-free resin composition, crosslinked insulated wire and cable U.S. Patent No.: 9,627,099 Patent date: April 18, 2017 Filed: Nov. 3, 2015 Assignee: Hitachi Metals, Ltd., Japan Inventors: Makoto Iwasaki, Ryutaro Kikuchi, Mitsuru Ryutaror A crosslinkable halogen-free resin composition includes a polymer blend, and a metal hydroxide mixed in an amount of 120 to 200 parts by mass per 100 parts by mass of the polymer blend. The polymer blend includes a maleic anhydride-modified high-density polyethylene, 30 to 50 parts by mass of an ethylene-acrylic ester-maleic anhydride terpolymer, 5 to 20 parts by mass of a maleic anhydride modified ethylene-.alpha.-olefin copolymer and 10 to 30 parts by mass of an ethylene-acrylic ester copolymer.

Cable bead manufacturing method and apparatus therefor U.S. Patent No.: 9,624,070 Patent date: April 18, 2017 Filed: Aug. 10, 2012 Assignee: Bridgestone Corporation, Japan Inventor: Yuichi Yoshida r The invention provides a method and apparatus for easily and efficiently manufacturing a cable bead, which features excellent wire winding performance. In this method, an annular core is held by a core rotating means. Then a reel wound with a wire is revolved in one direction through the inside and the outside of the core by a reel revolving means by holding the reel wound with a wire alternately on one side and on the other side of the core. And a wire is wound helically around the core as the core is rotated in a circumferential direction in association with the revolving motion of the reel.

MAY 2017 | 19

PATENTS

Cable U.S. Patent No.: 9,633,762 Patent date: April 25, 2017 Filed: June 19, 2015 Assignee: Yazaki Corporation, Japan Inventor: Yoshikazu Nagashima Provided is a cable enabling to reduce leakage flux and to restrict an increase of high-frequency resistance. A magnetic shield is provided to enable to reduce leakage of magnetic flux to an outside, and two first conductive wires and two second conductive wires having different phases from each other are adjacent to each other and arranged annularly to enable to disperse the magnetic flux, to restrict a proximity effect, and to restrict an increase of high-frequency resistance.

PATENTS

Cable gathering device (wire stacker) U.S. Patent No.: 9,624,045 Patent date: April 18, 2017 Filed: Nov. 9, 2012 Assignee: Schleuniger Holding AG, China Inventor: Thomas Wortmann The invention relates to a cable gathering device (wire stacker) (12) for processing electrical or optical lines (8), such as wires, cables, line bundles, optical fibers etc. comprising a platform (2) which can be tilted downwards which has an accommodating region (2a) for accommodating one or more lines (8) after a processing step, characterized in that the platform (2) has a removal region (2b) adjoining the accommodating region (2a), wherein lines (8) located in the accommodating region (2a) can be brought into the removal region (2b) by tilting the platform (2) downwards, from which the lines (8) can be removed and wherein the lines (8) are retained in the removal region (2b) by retaining means (2d) in the tilted position of the platform (2).

Method for producing spring U.S. Patent No.: 9,623,475 Patent date: April 18, 2017 Filed: July 12, 2011 Assignee: Chuo Hatsujo, China Inventors: Yuichi Hirata, Hidekazu Suzuki, Hiroyuki Ogiso A method of producing a spring which reduces time required for a heat treatment step of eliminating a machining strain generated by a forming step is provided. This production method is provided with a forming step (S10) of forming a spring steel material into a spring shape and a heat treatment step (S12) of eliminating a machining strain generated in the spring steel material by the forming step.

The heat treatment step is executed by electrically heating the spring steel material by applying a current thereto. The heat treatment step has a first step of heating the spring steel material to a predetermined set temperature and a second step of keeping the spring steel material at the set temperature for a predetermined set time period subsequent to the first step. The set temperature is set to be higher than 430.degree. C. but not higher than 500.degree. C.

Sensing cable with parallel spiral transmission line structure for distributed sensing and measuring of rock-soil mass deformation U.S. Patent No.: 9,618,644 Patent date: April 11, 2017 Filed: Nov. 13, 2012 Assignee: China Jiliang University, China Inventors: Renyuan Tong, Qing Li, Ming Li, Xiong Li, Ge Shi This present disclosure provides a sensing cable of parallel spiral transmission line structure for distributed sensing and measuring of rock-soil mass deformation. A circular cross-section of a silicone strip is tightly wounded by two mutually-insulated wires. The two mutually-insulated wires form the spiral cable. The two mutually-insulated wires are wrapped around and covered by a silicone shroud. They constitute a sensing cable. A termination matching impedance is connected to one end of each of the two mutually-insulated wires. A time domain reflectometry measurement instrument is connected to the other end of the two mutually-insulated wires. The present disclosure implements a distributed positioning and measurement of rock-soil mass deformation.

Spring steel and method for manufacturing the same U.S. Patent No.: 9,618,707 Patent date: April 11, 2017 Filed: Nov. 8, 2013 Assignee: JFE Steel Corporation, Japan Inventors: Minoru Honjo, Kazukuni Hase, Hideto Kimura Disclosed is high strength spring steel that can limit the depth of pitting occurring when corroded and therefore possesses high strength as well as excellent pitting corrosion resistance and corrosion fatigue property, with a composition containing: C: greater than 0.35 mass % and less than 0.50 mass %; Si: greater than 1.75 mass % and less than or equal to 3.00 mass %; Mn: 0.2 mass % to 1.0 mass %; Cr: 0.01 mass % to 0.04 mass %; P: 0.025 mass % or less; S: 0.025 mass % or less; Mo: 0.1 mass % to 1.0 mass %; and O: 0.0015 mass % or less, under a condition that a PC value calculated by PC=4.2.times.([C]+[Mn])+0.1.times.

(1/[Si]+1/[Mo])+20.3.times.[Cr]+0.001.t- imes.(1/[N]) is greater than 3.3 and equal to or less than 8.0. Also disclosed is a preferred method for manufacturing the same.

Evaluation of interference affecting a cable U.S. Patent No.: 9,614,559 Patent date: April 4, 2017 Filed: Dec. 19, 2013 Assignee: Telefonaktiebolaget L M Ericsson Sweden Inventor: Jacob Osterling A method for evaluating interference affecting a cable between a network node and at least one remote radio head.

20 | WIRE JOURNAL INTERNATIONAL

PATENTS The method is performed in the network node and comprises the steps of determining a set of wireless devices to be associated with the cable; obtaining a plurality of signal quality estimates associated with each one of the wireless devices of the set of wireless devices; averaging the signal quality estimates for the set of wireless devices, yielding an average signal quality; and determining interference affecting the cable based on a spectral analysis of the average signal quality.

Cable having electrical shielding and seal ) U.S. Patent No.: 9,613,731 Patent date: April 4, 2017 Filed: Sept. 12, 2013 Assignee: TE Connectivity Germany Inventor: Guenter Feldmeier The invention relates to a cable (1) having at least one electrical line (2), the electrical line (2) being surrounded by an electrically conductive sheath (5), the sheath (5) being formed from an electrically conductive and resilient sealing material.

Wire stripper with clamping device U.S. Patent No.: 9,608,416 Patent date: March 28, 2017 Filed: July 10, 2014 Inventor: Xiaozhong Zhang An insulated wire clamp device as disclosed for a wire stripper machine comprises a first beveled rotary collar on a first side of a shank and a second beveled rotary collar on a second side of the shank having a cutting blade there between. The collars comprise a first clamp and a second clamp of an insulated wire in a complementary V-shaped wire drive wheel. The wire drive wheel comprises a third and a fourth clamp of the wire on inner sides of the V-shaped wire drive wheel and the cutting blade comprises a fifth clamp of the wire in a cutting plane thereof. Shank spacers between the first collar and the rotary cutting blade and between the second collar and the rotary cutting blade add predetermined and incremental spacing options between three of the five clamps in the cutting plane of the insulated wire in the wire stripping machine.

(section contâ&#x20AC;&#x2122;d. on p. 66)

MAY 2017 | 21

ASIAN FOCUS

ASIAN FOCUS Scathing report finds little substance to Chinese cuts in its steel production

surveys carried out by the consultants.” Its findings and summation are as follows.

A total of 10 Chinese provinces increased their operChina officials have announced that they are reducing ating capacity, led by Shanxi and Hebei. The Beijing steel production at older, less-efficient plants to both region (Beijing-Tianjin-Hebei) saw a significant net upgrade the industry technology as well as reduce enviincrease, with both of Beijing’s neighbors increasing their ronmental concerns, yet the accuracy of those claims has capacity. Only six provinces achieved a fall in operating been questioned. capacity, with the A report in the largest decreases Washington Post said taking place in the that China—which Southwest and in accounts for half of Shandong. global steel producThe shortcomings tion—has total capacof the overcapacity ity of 1.1 billion mt. It reduction effort, reported that in 2016, it apparent in 2016 exceeded its initial tardevelopments, get of cutting capacity threaten to underby 45 mmt, with cuts of mine the effectivesome 85 mmt. ness of the entire A report, “Research policy of cutting Report on Overcapacity excess industrial Reduction in China’s capacity, unless Steel Industry,” from A map showing the Indigo cable route that will connect Singapore, addressed soon.

Custeel, a Chinese Indonesia and Australia. Superloop image.

Most of the capacmetallurgical industry ity elimination tarconsultancy, was commissioned by Greenpeace East Asia. get set for the 2016-2020 period has, technically, already The research led to the following conclusion: steel probeen achieved in 2016, meaning that capacity elimination duction capacity in China actually increased in 2016. The in 2017-2020 will be much more modest unless targets report noted the following. are increased. Meanwhile, a 21 mmt capacity increase is ● Most of the eliminated capacity was already closed still in the pipeline from new projects, and there is at least down or idle, meaning that only 23 mmt of actual 42 mmt of existing idle capacity that could be used to fuloperating capacity was closed. fill the capacity elimination targets. ● 49 mmt of steel capacity that had previously susWhether China’s operating steel capacity increases or pended production was restarted as the capacity decreases over the current five-year plan period depends closures curtailed supply and government stimulus on whether the remaining capacity cuts continue to target increased demand. The restarted capacity was equal to idle capacity or if it actually refocuses to eliminate actual Germany’s total steelmaking capacity. operating capacity. ● 12 mmt of new capacity was added, further offsetting In the best-case scenario, if all the capacity eliminated some of the reduction. in the coming year is operating capacity and no restarts “As a result, China’s operating steel production capacity of previously closed capacity take place, operating steel increased by 36.5 mmt in 2016, even as a vast amount of capacity could fall by approximately 66 million tonnes in largely idle capacity was eliminated,” the report said. The 2017-2020. This would put the total reduction during the increase in operating capacity is more than twice as large 13th FYP period at 30 mmt, a modest amount compared as the total steelmaking capacity of the U.K. Also, 75% of with the 100-150 mmt reduction targeted in total capacity. the capacity restarts and 80% of the net increase in capacAs China’s domestic steel demand is projected to fall to ity took place in just three provinces neighboring Beijing: 650-700 mmt from 2016-2020, China should: seek actual Hebei, Shanxi and Tianjin. Further, capacity reductions reduction in steel supply; prevent future restarts of closed do not necessarily translate to lower production. China’s down capacity by demolishing the facilities; investigate steel production for 2016, 808 mmt, was up 1.2% from local governments subsidies, loans and interventions that the prior year. have prevented market mechanisms and bankruptcy proCusteel noted that it “mapped changes in operating cedures; prioritize the elimination of inefficient and highcapacity in 2016 in unprecedented detail, based on docly polluting capacity; and make full use of the bankruptcy uments from provincial governments as well as industry mechanism to eliminate capacity at zombie companies.

22 | WIRE JOURNAL INTERNATIONAL

Australian company Superloop has acquired subsea cable operator Subpartners and reported related plans for a new cable—Indigo, to be supplied by Nokia’s Alcatel Submarine Networks (ASN)—linking Singapore and Indonesia with Australia.

Per a press release at Superloop’s website, Superloop Limited announced its acquisition of SubPartners Pty. Ltd., which was established “to develop high performance secure international cable systems capable of providing improved connectivity between Australia and the rest of the world.” The consortium is constructing the Indigo West cable (Singapore to Perth) and the Indigo Central cable (Perth to Sydney).

Indigo will be 9,000-km long, connecting existing facilities in Singapore, Indonesia and Australia, where it will land in Perth and Sydney. Each of the two fiber pairs will have a minimum capacity of 18 Tbps. The design will enable the system to have increased capacity. The cable system is currently expected to be completed by mid2019.

Once the Indigo cable system is completed, Superloop said it will have access to 4.5 Tbps capacity via the fiber, which it will be able to increase over time. The acquisition, which was said to cost $2.5 million, will also deliv-

ASIAN FOCUS

Superloop reports acquisition, plans for Asian cable with ultra-high capacity

A map showing the Indigo cable route that will connect Singapore, Indonesia and Australia. Superloop image. er Superloop “a team with substantial submarine cable experience and an ability to lead or participate in other future potential undersea cable investments,” the release said. The consortium members include AARNet, Google, Indosat Ooredoo, Singtel and Telstra.

Google reported that the Indigo will serve Google traffic between Australia and Asia, connecting Perth, Sydney and Singapore, with a branch to Jakarta. “Google has made seven submarine cable investments in total (this is our fifth in the region) more than any other cloud.”

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PEOPLE

PEOPLE Alps Wire Rope Corporation reported three promotions and one retirement. Mike Briand has been promoted to national sales manager. He has been with the company for five years and in the wire rope industry for more than 30 years.

He previously served as vice president of Yoke North America. He fills a position Briand that became open with the resignation of Jeff Marterella, who joined the company in 2010. Previous employers include Casar America, WirecoWorldgroup, Alpswirerope, Wire Rope Industries, Paulsen Wire Rope Corp. and Nelson Wire Rope Corp. Ross Benner has been promoted to regionBenner al manager for the North Central area. He has been with Alps for more than 21 years and previously held the positions of purchasing manager and customer service. Bill Lee has been promoted to regional manager for the South Central area. He joined the company 11 years ago as a sales representative. He has 36 years of industry Lee experience with past employers that include NOV and MacWhite, among others. Based in St. Charles, Illinois, USA, Alps Wire Rope Corporation supplies wire rope, cable and strand products.

Michael Blaha has joined American Wire Group (AWG), as director of utility sales, responsible for sales and marketing of products for electrical utilities in North America as well as for expanding sales of high-voltage underground cables. He has 26 years of industry experience. He previously worked for Nexans High Voltage USA, Blaha Inc., as its northeast and mid-Atlantic regional sales manager for high-voltage land cables and responsible for subsea cable and installation in North America. Other past employers included Marmon Utility–Kerite and FCI-Burndy. He holds a degree in earth science and mathematics from Southern Connecticut State University. Based in Miami, Florida, USA, American Wire Group, supplies a wide range of wire and cable products.

24 | WIRE JOURNAL INTERNATIONAL

Inka Guixà was named managing director of La Farga, responsible for all the industrial companies that are part of the metallurgical holding company. In 2009, she joined the company as expansion director of the metallurgical holding company. In 2012 ,she was appointed managing director of Guixà La Farga Intec, and the next year she became managing director of strategic planning and management of the metallurgical holding company. She holds a degree from ESADE and a master’s degree in business administration. Prior to joining La Farga, she worked at the Damm Group, Antares Consulting and Novartis Pharmaceuticals SA. While she has become the top company executive, Oriol Guixà will continue as chairman and CEO of the company. Based in Spain, La Farga manufactures some 192,000 metric tons of copper products a year.

Chemetall US Inc. announced that Neil C. Lowdon has joined the company’s Cold Forming Group as business development manager, responsible for growing strategic sales in wire, cold heading, tube, pipe and extrusion markets. He has more than 15 years of industrial sales experience, including serving the last two years as general sales manager Lowdon at Condat Corporation, a specialty lubricants manufacturer. He previously spent some 21 years in wire manufacturing within the Bridon group of companies (in both the U.S. and U.K.), where he held key positions. Based in New Providence, New Jersey, Chemetall US Inc. (a division of BASF) supplies a wide variety of surface treatment and coating solutions for the metal forming industries.

Cable Components Group has named Jacob LaBelle as compound development supervisor. After completion a six-month immersion program in both compounding and extrusion, he will be asked to take over responsibility for supervising all aspects of compounding. He previously worked for Global Application Technology. He holds a B/.S. degree LaBelle in chemical engineering and a master’s degree in material science and engineering. Based in Pawcatuck, Connecticut, USA, Cable Components Group supplies extruded products for wire and cable.

George W. (Dick) Richards III, a former president of G. Whitfield Richards Co., an industry supplier of lubricants, died March 30 at age 76.

Richards, who ran the family business but also found time to serve as president of the Wire Association in 1986-87, was known for his dediRichards cation to the industry. He lived outside of Philadelphia, Pennsylvania, during his working years while he and his wife, Bonnie, raised their family. Starting out in sales, he advanced to president of G. Whitfield Richards, Co., founded in 1902. In 1997, the company merged with Apex Alkali Products Co., founded in 1933, to create RichardsApex.

Above: from l-r at the 1987 Spring Meeting of the Wire Association’s Nonferrous and Electrical division in Manchester, New Hampshire, were (l-r) 1st VP J. David Beneke, meeting chairman Frank Miller, and Association President George W. Richards III. Outside of work, Richards was involved in local groups, from the Boy Scouts to the local community center. After he retired, he and Bonnie moved to “Someday Point,” outside of Oxford, Maryland, where he golfed at the Talbot Country Club, served on the Membership Committee of the Tred Avon Yacht Club, was commodore in 2012 of the Poplar Islands Yacht Club and was on the board of the Oxford Community Center. He was an avid outdoorsman, especially when it came to fishing, hunting and boating, who loved to feed and watch birds, as well as raise koi in his pond.

“Dick was a great friend,” said John Bowles, WAI president in 1995-96. “I am honored to have known him.

He is a fine example of a life well lived!”

“Dick Richards was a friend, mentor and a consummate business man,” said John Drummond, WAI president in 1997-98. “He leaves a legacy of integrity and involvement in both the wire industry and WAI that is significant, ongoing, and to a large extent not fully recognized, except by those close to him.”

The family legacy continues at RichardsApex, which became international in scope. Today, the business is led by two of George Richard’s three sons: David Richards, COO, and Andrew (Drew) Richards, CEO. His third son is George W. (Whit) Richards IV. Richards is also survived by his wife of 55 years, Bonnie; three daughters-in-law, Kati, Janis and Andrea; and two sisters, Deborah Deschamps and Paula Tobin; and seven grandchildren.

Kenneth (Ken) J. Scott, a retired U.K. industry veteran and a good friend of the WAI, died March 27, 2017, from cancer.

Scott, a long-time employee of Holton Machinery, Ltd., served as managing director of Luvata Holton Limited from 1996 to his retirement in 2003.

He was a member of the WAI’s Board of Directors Kenneth Scott serves as the from 2005-2010 and clockwinder at WAI headchaired the England comquarters in 2001. mittee for an International Technical Conference that was done in conjunction with Wire Association International.

WAI Executive Director Steve Fetteroll recalled how Scott came to Association headquarters for the Clockwinding in May 2001, accompanied by his wife, Jean, who had written a poem, “A Timely Ode to the Clock,” that she recited. Post 9-11, Fetteroll traveled to Singapore, where Scott greeted him, and met him again later that year in the U.K. for the conference, and both times was impressed. “Ken was not just the chair but also a speaker. That event sparked a terrific period of collaboration with a number of other international industry groups and resulted in six joint conferences throughout Europe. Ken understood the industry and was a visionary when it came to the Association. He was truly generous in his support, serving two consecutive terms on the Board.

Scott is survived by his wife, and daughter, Natalie.

Frank Cardile, the founder of InterWire Products, died at home in Purchase, New York, on Nov. 23, 2016, at age 81. Born in Tripoli, Libya, he attended the University of Naples in Italy and earned a Master’s degree in law from Hunter College in New York. In 1981, he founded InterWire Products in Armonk, New York, a distributor of wire products and materials.

Survivors include his wife of 28 years, Deborah Cardile; and three children from his first wife, the late Teresa Joy Cardile: Roseann Cardile, Lisa Cardile and Deborah Cardile Monaghan. He was predeceased by a fourth child, son Frank Cardile, Jr.

MAY 2017 | 25

PEOPLE

OBITUARIES

FIBER WATCH

FIBER WATCH ‘Copper’ destination turns to fiber to improve its cold-weather attraction It’s a small story, one that calls for a mere two miles of optical fiber, but it is a telling story: the ability to provide better cell service anywhere, including atop a 9,000-ft-high ski resort, is an expectation.

Sharing a good day of skiing is part of the experience.

The proprietors of Copper Mountain had AT&T install two miles of fiber optic cable at the popular ski destination, which is located in Summit County, Colorado. In a CBS Denver report, AT&T’s Quin Gelfand said that “now the antennas are closer to people, which means that it’s easier to access for everyone, and that way more data can

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be processed, and more people can have a better, faster experience.”

The driver for the project was to give Copper Mountain a social media boost, and the resort reports that goal has been accomplished: since February, the equivalent of activity there has been the equivalent of 20 million social media posts.

“We want people to share their experiences here, and let us know that they’re having a great time,” said Copper Mountain’s Steph Sweeney. “It’s really great that they can share social media posts.”

Offering more is important. While skiing is an exhilarating experience, the industry has been challenged.

The 2015-16 season saw 53.6 million visits by skiers/ snowboarders, up from the prior year but well short of the 2010-11 season, which saw 60.5 million visits. More ski destinations are seeking to make the experience better.

One such site is Breckenridge Ski Resort, also in Colorado, which plans to bury 735 ft of fiber optic cable and build four 35-ft towers that will be disguised as trees.

The fiber optic cable would be installed in previously undisturbed areas at the Peak 9 restaurant, Ten Mile Station and Colorado SuperChair. Resort staff states the upgrade, which requires replacement of existing towers, terminals and accessory components, will increase capacity on Breck’s southern-most peak by 25%. The goal? To improve both wait times and bandwidth.

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New fastener event to be held in 2018 Mack Brooks Exhibitions Group announced that it plans to launch a fastener event in the U.S. next year.

A press release from the U.K.-based organization said that the first staging of Fastener Fair USA will take place April 11-12, 2018, at the Huntington Convention Center in Cleveland, Ohio. Described as a “unique industrial fastener and fixing show,” Fastener Fair USA will bring together manufacturers, distributors, suppliers and end users in the region’s only dedicated fastener, fixing, and joining technology exhibition.

The show, the release said, “will offer a first-hand look at the latest solutions and technology available in the marketplace, as well as a top-notch educational program developed and delivered by industry experts.” There will also be networking events to facilitate relationships and collaborations with industry peers.

“The idea to bring Fastener Fair to the U.S. market originated within the fastener industry,” said Melissa Magestro, executive vice president of Mack Brook Exhibitions, Inc. “There is an increased need to find new technologies and suppliers in the U.S., and fastener OEMs and distributors are looking for a platform to showcase their solutions. We are bringing the Fastener Fair experience to the heart of the Midwest manufacturing region.”

A unique feature of Fastener Fair USA will be the

Fasteners Direct Pavilion, where manufacturers can showcase their solutions for OEM engineers, designers, buyers and R&D professionals all in one convenient location. The show will also offer exclusive, technical education sessions specifically to address the product design challenges of OEM end users.

Exhibitors from around the world are expected to participate in the inaugural Fastener Fair USA 2018, the release said. It noted that the main product categories include: industrial fasteners and fixings; construction fixings; assembly and installation systems; fastener manufacturing technology; storage, distribution, factory equipment; and information, communication and services.

The release cited a positive sector outlook for the sector, noting that forecasts call for GDP growth to remain steady through 2020, with U.S. industrial manufacturing continuing to be strong. Per a 2016 study on Industrial Fasteners by the Freedonia Group, the U.S. market for industrial fasteners is expected to increase 2.6 percent per year to $15.2 billion in 2020, it said.

Mack Brooks Exhibitions Group puts on a series of Fastener Fair events. For more details on the first staging of Fastener Fair USA, either go to www.fastenerfair.com/usa or (in the U.S.) call tel. 866-899-4728 or 312-809-9260.

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MAY 2017 | 27

FASTENER UPDATE

FASTENER UPDATE

WAI NEWS

WAI May 2017

MEMBERSHIP

SPOTLIGHT This section introduces a new WAI member each issue.

Pati Kelly Executive Recruiter Egret Consulting Group

Q: What does your company do?

A: Egret Consulting Group is the largest U.S. search firm dedicated solely to the electrical industry. In the past 17 years, we have placed over 700 new employees at over 100 clients in manufacturing and distribution.

Q: What is your role there?

A: I work specifically in the wire and cable segment of the industry. I have placed vice presidents of sales, regional sales managers, plant managers, product managers, design engineers and process engineers. .

Q: What do you like best about your position?

A: I can make a difference in a company’s future growth and also someone’s life. When you find a candidate who is the right fit for a company and he/she makes an impact there, and the employer later thanks you for finding that person, it is a great feeling.

Q: How has your industry most changed?

A: There are a lot of technical changes—from alternative energy and distributed generation to outsourcing and the rising influences of technology, such as the IoT/Smart Factory—but we see other big challenges.

Leadership is changing as many owners and senior managers retire, and we need to find new talent that can lead the industry into the future, and there is competition from other sectors. For more on that, see p. 36.

Q: How does your company remain competitive?

A: We strive to be knowledgeable of industry trends; we do that by talking to leaders in the industry and following the news that is specialized to our industry. We also try to educate our clients on hiring practices and salary compensation ranges.

Q: Why did you recently join WAI? A: We like to be knowledgeable of the industry segment we are part of. Since I am Egret’s wire and cable expert, I want to be involved in the organizations that work within my industry. WAI helps me do that.

28 | WIRE JOURNAL INTERNATIONAL

The following individuals either recently joined WAI or became Platinum Members through their companies.

Iracema “Sema” Brown Sales Representative Teknor Apex Co. Maria Buitrago Isonyx Systems LLC

Ron Frank Senior Sales & Service Representative Freiborne Industries Inc.

Tzyy-Shuh Chang President OG Technologies, Inc.

Matthew Gailey Technical Manager Laser Additives EMD Performance Materials

Salvatore De Chiara Operations Director SAMP SpA (SAMPSISTEMI)

Phillip Guthrie President Leading Edge Metals & Alloys, Inc.

Keith D’Amato Vice President Sales & Marketing Sjogren Industries Inc.

Ryan Johnson President ZD Wire Products

Doug Deuce Business Development Engineer Sikora International Corp.

Jim Kelly Northeast Regional Sales Manager Mexichem Specialty Compounds Inc.

Seth Dukes Process Engineer Copperweld Bimetallics

Pati S. Kelly Executive Recruiter Egret Consulting

Robert G. Kepes President Tensor Machinery Ltd. Christopher J Lambert Purchasing Manager Specialty Cable Corp.

Jonas Larsson Metallurgist Nexans Norway Marta Rota VARO Juha Saily Sales Manager FocalSpec, Inc.

Samantha L. Szymaszek Membership Services Representative Wire Association International Stephen Voss AM Stabilizers Corp.

Gordon Wood Director Sales & Marketing Carris Reels Inc. Stephen Wright Blachford Corp.

Paul Suarez Project Engineer The Pilot Group Cristian Saraceno Sales Manager Tramev Srl

MAY 2017 | 29

WAI NEWS

MEET YOUR PEERS. ACHIEVE YOUR GOALS. JOIN WAI TODAY.

Wire is everywhere.

Play.Watch & Share.

The Wire Association International, Inc. Telephone: (001) 203-453-2777 | www.wirenet.org

WAI NEWS

From the WAI Ferrous Wire Handbook With 36 chapters over 1,168 pages, the Ferrous Wire Handbook, published in 2008, remains the Association’s most-ever comprehensive literature project, written by three dozen wire industry experts and edited by former WAI President Robert M. Shemenski, an industry consultant and president of RMS Consulting, Inc. The book is a modern-day reference tool for those working directly in the steel wire or manufacturing, engineering and operations sectors of the industry. The chapters present straightforward explanations of different process, supported by charts and photos. The content covers a full spectrum of sectors, with individual chapters—from wire rod production and deformation in cold drawing to patenting and straightening and cutting wire—that explain the process in practical terms. A company that just wants one or two chapters need not pay for the entire book ($235/$195 for WAI members).

A PDF of a single chapter, from 4 through 36, can be ordered for $25, $20 for WAI members.

Each order will include an additional free PDF with the first three chapters (A short history of the Ferrous Wire Industry, Evolution of Modern Steel Manufacture, and Modern Steel Manu-

facturing), which serve as an industry introduction and overview.

To get the first three chapters for free, go to www.mywai.org. There you can see and order the other individual chapters. Future issues will present additional chapter summations here.

CHAPTER 13: Wiredrawing Equipment

ON SALE NOW!

SUMMARY: This chapter, 60 pages, discusses the subjects in the below subheads. It includes approximately 50 pictures and figures as well as a bibliography.

Types of topics covered: • Single-block • Continuous Drawing • Basic Configurations • Electrical Configurations • Take-Up/Packaging • Related Equipment/Slip Machines • and more

MAY 2017 | 31

CHAPTER CORNER

CHAPTER CORNER Tee time nears for Midwest Chapter’s Golf Tourney, 2 others to soon follow The WAI’s Midwest Chapter golf tourney is just about a month away, which means that it is way past time for participants to get their swing tuned up, as bragging rights once again will be up for grabs.

The Midwest Chapter’s 15th Annual Golf Tournament will be held on June 16, at the St. Andrews Golf & Country Club in West Chicago, Illinois. Last year, Donald Stephanie and Robert Robinette, both from Western Engineered Products, shot a sparkling 11 under par to grab top honors. Contact: Steve Fetteroll, tel. 203-453-2777, ext. 115, sfetteroll@wirenet.org.

Two other WAI chapters will hold their golf tournaments in September. The New England Chapter will hold its 23rd Annual Golf Tournament on Sept. 12, at the Golf Club of Avon. The WAI’s Southeast Chapter will hold its 16th Annual Golf Tournament on Sept. 21 at the Rock Barn Golf and Spa, Conover, North Carolina. Conover,

Above: The Midwest Chapter’s 2016 winning team of Donald Stephanie, l, and Robert Robinette, both from Western Engineered Products.

North Carolina, USA. For both those events, contact Steve Fetteroll, tel.203-453-2777, ext. 115, sfetteroll@ wirenet.org.

Each of the above golf tournaments offers a range of sponsorship opportunities. They also serve as fundraisers for their respective chapter college scholarships, so taking part is not just fun, it’s supporting a good cause.

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FEATURE

Professional Development

How companies attract and maintain a workforce that is able to meet the needs of their businesses is essential. What Prysmian has done in that regard is remarkable in scope, but each company has to address this in some way. This feature presents observations from five other manufacturers, a look at generational challenges, details on apprenticeships and a Perspectives presentation on page 46 by an industry veteran.

Staffing: fielding good staffers has become increasingly challenging Whatever a company’s size, hiring, maintaining and preparing employee for the present and the future is a challenge. Below, representatives from five manufacturers share their thoughts on personnel, a topic that they agree covers a lot of turf.

WJI: Once a person is hired, what kind of training do you provide, and is that something that is ongoing?

All new employees are assigned a team to help them be successful in their new role. For our shop floor the team is very defined, including their immediate supervisor, a process engineer, and an on-the-job trainer. In addition all employees complete a one day orientation to introduce

Pelican Wire stages an annual “Pelican Cup” day, split between friendly competition and learning more about the company’s finances and direction. them to the company, the products, and our culture. Many of our employees also take advantage of “University of Pelican,” a way in which we encourage employees to invest in their own training, and to train others. We have set “courses” through UoP, and some are developed as needed. Skill transfer is critical. We find that the more our employees get exposure at all levels, the better we are as a whole company. Ted Bill, president, Pelican Wire.

Once hired, the new employee is trained to perform to our company standards. We attempt to merge their particular skill set with our team. Actually, I consider 34 | WIRE JOURNAL INTERNATIONAL

training to be a two-way street. If they’ve created a strong enough impression to get hired, then we would be open to new ideas and perspectives. A fresh pair of eyes can see things that current employees cannot. A new employee’s experience and background could help us become more effective and efficient. We monitor each employee’s performance. If we determine additional training will result in greater productivity, we will provide it. To date, we have provided all training internally. Edward Boyle, president, Imperial Wire & Cable Co. Training may be one of the most important needs that tends to be ignored in companies. We assume the person should have the skills to perform the job and expect then to adapt and learn as the grow In their job. I would love to say we have an extensive, ongoing training program, but smaller companies most often lack resources to provide effective training. While we are part of a large organization, our processes and products are very unique to our much smaller company which doesn’t allow for industry specific training. Most of this training is done through various interactions with experienced employees and on-the-job training. Brian Burr, president, Sumiden Wire Products Corporation.

The level of training depends on which department the person is hired into. For sales, there is extensive training with our sales trainers. The training for sales is ongoing, as there are sales mentors to help as salesman move up through the company. For departments like accounting and marketing, there is training on how to best perform that position, and how to utilize the software and tools that the company provides. Warehouse positions also go through lots of learning from our Director of Training and Development, who specializes in training all new warehouse employees. Tim Flynn, president, Allied Wire & Cable.

FEATURE The Prysmian Group Academy was created to groom key staffers for both production and for management positions.

Prysmian: the search for talent led to the creation of its own school Five years ago, Prysmian created the Prysmian Group Academy, a corporate university to groom future leaders in the energy and telecom cable industry, both for production and for leadership.

The School of Management seeks to strengthen leadership and management skills. Created in partnership with SDA Bocconi, it benefits from collaboration with business schools that include SMU (Singapore), Fudan University (China), University of South Carolina (USA), FGV EAESP (Brazil), Steinbeis University (Germany), Corvinus University (Hungary), ESADE (Spain), ESSEC (France), and Stockholm School of Economics (Sweden).

The Professional School, a technical school with nine disciplines and 35 courses, is aimed at developing and strengthening skills through their transfer from the most senior staff to their younger counterparts. The School also draws on several of the Group’s centers of excellence, such as the Manufacturing Academy inaugurated at the plant in Mudanya, Turkey, in 2016.

“The value created by the Academy is very high,” said Dr. Angela Amodio, People Development Human Resources and Organization, Prysmian Group.

“Employees deeply appreciate it as a tool of development and we would like to continue to invest in it.”

Prysmian has also been active at promoting the Academy and a career in wire and cable to people outside of the industry, via its recruiting program: “Make It: A Manufacturing Career at Prysmian Group.” It seeks to identify 50 relatively new manufacturing professionals from around the world. These engineers and technical specialists come from outside the cable industry and have an average of five years’ work experience in manufacturing, operations, and quality functions. The program begins with a two-week induction, the first week in Milan, during which participants learned about Prysmian Group as a leading cable company, and the second at the Mudanya Manufacturing Academy’s centre of excellence.

There, they get to meet and interact with Group managers.

The program introduces the engineers to the cable industry—which is new to most of them—while providing the basics of cable design, machinery, and processes specific to the industry.

“Our ‘Make It’ program represents the first time we have taken such a unique approach to recruiting and onboarding,” said Fabrizio Rutschmann, HR Senior Vice President at Prysmian. “This is quite different from the typical spot-recruitment efforts, where we hire professionals from within the industry.”

WJI: Do you see your company size as a plus or a minus in terms of your being able to attract the right kind of employees, especially for key leadership positions?

Regardless of the company size, the most important characteristic is cultural fit. Our size is certainly part of our culture, so from that standpoint size does matter. But we don’t see it as a benefit or liability.

Ted Bill, Pelican Wire.

A definite plus! By having a smaller workforce we can appeal to prospective employees by offering a less formal organizational structure. All employees can have direct contact with management on a daily basis. They have greater input in decision making without the red-tape that larger organizations

Edward Boyle, Imperial Wire & Cable Co. have to deal with. We put forth more of a family or team approach as opposed to a corporate climate. Edward Boyle, Imperial Wire & Cable Co. MAY 2017 | 35

FEATURE

Our headquarters, based in Collegeville, Pennsylvania, has fewer than 200 people working in our main business campus. If we are unable to promote internally, we look for the best available candidate. Most people are delighted to work with us. We have a great atmosphere and receive yearly awards for being one of the best family run businesses in the Philadelphia area. Take great care of

your employees and they will take great care of your customers. Tim Flynn, Allied Wire & Cable.

Insteel has experienced employees from large companies and small companies who have found our company to be a good fit and contribute successfully. We find that an individual who has a high performance focus and a collaborative, transparent way of working is attracted to

Talent search: a timeless challenge Pati Kelly, an executive recruiter for Egret Consulting Group (pk@egretconsulting.com), focuses on wire and cable. Below she shares her thoughts with WJI. Also, see p. 28.

WJI: Is there a talent shortage in the wire and cable field? If so, has it gotten worse in recent years?

Kelly: I think that there is a shortage of wire and cable talent entering the field, especially when we talk about engineers. A lot of students go into industrial engineering, but we can’t seem to find enough process engineers who are interested in the field, so more companies are trying to grow their own, hiring college interns and then having them come on full time after graduation.

WJI: Is wire and cable an especially tough sale for young talent that has not previously worked in the sector?

Kelly: Wire and cable companies might not think it, but they are competing for talent with companies such as Apple, Microsoft and Amazon. Most young engineers want to work in the sexier industries, like automation and software. Unless they had a college internship in the field, recently graduated engineers are not likely to think about working in the wire and cable industry. Most seem to come through prior ties, such as friends or family who worked in it, and some were recruited on campus.

WJI: Pay is obviously a major key, but are there other elements that younger candidates want?

Kelly: When it comes to younger candidates, flexible work schedules and vacation time matter a lot, but it’s more than that. If a company is on-board with a mentoring program, has team-building events, offers expanded responsibilities and challenges so a person can grow in their career, and also recognizes work that was well done, they will have a higher retention rate for their new hires.

It also helps to have the latest in technology and communications tools so that telecommuting is a possibility.

WJI: Can you assess whether a Generation Y (or Z) candidate will want to stick with a company for more than a year? Is “loyalty” a word that no longer applies?

Kelly: I wish there were a magic formula for that, but it seems that there is not much loyalty within the workforce in general. What I do see is that most candidates want to have a more definite career plan, one with a target time-

36 | WIRE JOURNAL INTERNATIONAL

frame for career advancement, there is not much patience for sitting in one position for five to 10 years. Younger employees want to be challenged and mentored to help them gather the skills to move up on the corporate ladder.

Kelly They also want to know that their efforts are valued and recognized for their contribution. When we look at Gen Y, they are coming into the work force with huge college debt that the baby boomers or other generations never had, so they are concerned for their financial well being, so if they can make a job change and get a 10% pay raise in the next two years why would they not?

WJI: In terms of filling a position with a veteran, are there more retirements than qualified candidates?

Kelly: The supply/demand ratio is different depending on the position and what segment it is. Finding a process engineer with 10 years of experience is not easy but finding a regional sales manager with that same experience is much easier. I think the real challenge is bringing in entry-level college students in the outside sales role or design engineering role, and then getting them to stay. We need to be able to show younger candidates that there is growth. The problem there is that most of them probably just think wireless, and don’t see how that is also part of wire and cable. We need candidates to see and believe that there are exciting end uses for wire and cable, such as data centers, smart grids, utility micro grids, alternative energy, solar, battery storage, IoT, appliance power consumption, not to mention new car design like the Tesla, self driving cars all of these need wires and cables and assemblies to function. This is an exciting time to be part of wire and cable industry. Employers have to find ways to make that story real. Younger candidates are looking for more than what people were looking for 10-15 years ago. They want mentors, flexible work schedules, vacation and good salaries, but they also want a defined career path that will get them where they want to be.

to become more valuable. Brian Burr, Sumiden Wire Products Corporation.

I think the size of the company can have some impact on being able to attract the right kind of talent. Larger companies tend to have more resources which can be more appealing to candidates. However, I think the type of culture and the location of the company have a more significant impact on attracting the right candidates. A smaller company often provides a more diverse work experience and more entrepreneurial exposure, which can be very attractive to resourceful, creative talent. Brian Burr, Sumiden Wire Products Corporation.

Cultural fit is critical. We have established core values, if they don’t meet our values then there is no place on the bus for them, regardless of the experience or talents. Ted Bill, Pelican Wire.

WJI: If you are looking to add a key position, what leads your list in the attributes you look for, and why?

Caring, common sense, drive and leadership, knowledge. Most of these are inherent characteristics of individuals we are looking for, but our industry knowledge is the one factor that has to be learned. Tim Flynn, Allied Wire & Cable.

I seek individuals who have different backgrounds and experiences than my own and those of our current team.

I need people who can offer insights and perspectives which vary from my own. Edward Boyle, Imperial Wire & Cable Co. We have found that individuals who have a high performance focus and a collaborative, transparent way of working are attributes that lead to success. Christi Smiley, Insteel Industries, Inc. Key positions need to be able to make timely, effective decisions. The decision making attribute ranks high on the list of attributes required for key positions. Companies continue to do more with less people. The ability to take various personalities, goals and inputs and get to a decision which is best for the organization continues

WJI: How “set” are you in terms of filling a new position? Are you willing to either hire a new person or promote a staffer who does not have all the tools you need?

I would prefer to promote internally. I believe current employees should be considered for any new or newly available position. The exception would be if the new position requires a level of technical expertise that current employees do not possess. Edward Boyle, Imperial Wire & Cable Co. This is a difficult question. As in most cases, it depends on the scenario. I think there are positions where there is time to groom an up-and-coming employee. There are other positions where you require a great degree of skill and talent immediately. If we think a current staffer has the tools and the drive to succeed, we would promote the internal candidate over an outside candidate. Brian Burr, Sumiden Wire Products Corporation.

High potential in a known quantity is valued, even if development is needed. Christi Smiley, Insteel Industries, Inc. We LOVE to promote from within, particularly employees that have invested in themselves to be ready for the next step. Some roles require certain experience or skills that don’t exist internally, so you don’t have much choice but to go outside. But if an internal opportunity exists we do everything we can to make it happen. Ted Bill, Pelican Wire.

(Continued)

MAY 2017 | 37

FEATURE

Insteel. Christi Smiley, recruiting & employee development manager, Insteel Industries, Inc.

FEATURE

We always try to promote from within. Some tools can be taught. We have sent most of our leads and managers to some type of management program to help them improve their skill set. Tim Flynn, Allied Wire & Cable.

WJI: Do you require a new job candidate to take one or more tests? How many people might a candidate interview with?

Insteel utilizes one assessment during the selection phase. The number of people a candidate will interview with depends on the specific role but we employ a collaborative hiring approach, finding the process improves hiring outcomes. This team-based hiring results in a candidate interviewing with three to six people on average. Christi Smiley, Insteel Industries, Inc. We do not require a written or verbal test. We do have a 90-day probation period. During this time we evaluate their work, their work ethic, their productivity and their ability to interact with fellow employees and customers. Prospective employees would interview with one or two people, in addition to myself. Edward Boyle, Imperial Wire & Cable Co. We use several tools and profiling surveys, such as DISC profiles to help us better understand the candidate. Most candidates will be interviewed by anywhere from three to six employees, depending on the position they are applying for. Occasionally, we use outside expertise to evaluate the capabilities of the candidate, and to help us understand how they will fit in to our culture. Ted Bill, Pelican Wire.

Burr

We don’t necessarily require a test, but we frequently request them to take a personality test. This helps us understand more about how the person thinks and approaches issues, which can be difficult to uncover in an interview.

Typically, a key position would require multiple interviews, with a total of three to six people. Brian Burr, Sumiden Wire Products Corporation.

For sales positions, they might take up to three tests. Some other jobs require testing as well, but it really depends on what position we are filling to determine what we need to know about the candidate. The position will dictate how many interviews will be given, which can sometimes be up to three or four interviews. Tim Flynn, Allied Wire & Cable.

38 | WIRE JOURNAL INTERNATIONAL

WJI: As many staffers with decades of experience retire, how long does it typically take for a new hire to become a producer, and what, if anything, do you do to try and make sure that person stays?

Research shows that on average it can take anywhere from eight weeks for a clerical type position to 26 or more weeks at the executive level for a new, outside hire to reach full productivity.

At Insteel, the steps we take to help ensure a new team member chooses to stay are focused on establishing relationships with coworkers and the leadership team. Christi Smiley, Insteel Smiley Industries, Inc. I believe if you hire right a new hire can be a producer very quickly. Hiring for cultural fit is critical for the longevity of the employee. Ted Bill, Pelican Wire.

We are just getting to the stage where we will begin to have some experienced staffers begin to retire. For mid-level talent, it can take up to one year for a new hire to become truly productive. We feel as long as we do a thorough job on the front-end of screening employees and ensuring a shared similar culture, we can significantly minimize talent turnover. Brian Burr, Sumiden Wire Products Corporation.

Even though we are one of the largest wire and cable specialists in the nation, we are still fairly young, meaning we have not had to deal with too many people retiring as of yet. Tim Flynn, Allied Wire & Cable.

WJI: Has your approach to hiring, especially for management positions, changed much in the last 10 years?

Do you use electronic sites to seek candidates? Do you do an “electronic search” of a candidate?

Our approach has definitely changed from trade magazines, newspapers and recruiters to using internet based digital media sites. With the mass adoption of the smartphone, candidates expect to interact and apply for jobs at any moment and anywhere. Even though we have adopted a digital strategy for recruitment, word-of-mouth references from reliable, respected industry veterans carry a significant amount of influence in hiring decisions. Brian Burr, Sumiden Wire Products Corporation.

In many ways we have improved our search process.

We do use tools such as Linked In, Monster, etc., to look for candidates. On occasion we also use search firms. Ted Bill, Pelican Wire.

FEATURE

Insteel’s approach to hiring has definitely changed in the last 10 years. Electronic job boards have grown in both the number of options available as well as ease of use. Social media has also opened up a whole new avenue for finding candidates and for candidates to find out about us. There is more use of internal tools now, such as networking and reaching out to passive candidates.

Christi Smiley, Insteel Industries, Inc. We use every hiring tool available to us. Employment agencies, web, paper ads, signs on the street, internal bonuses. It has gotten a lot tougher to find the perfect candidate from just one site. Tim Flynn, Allied Wire & Cable.

WJI: Have you ever considered taking part in an apprenticeship program? If not, do you have any specific reservations? What might convince you to do so?

I have not previously considered taking part in an apprenticeship program but would consider participating. Edward Boyle, Imperial Wire & Cable Co. We’ve worked with the Chamber of Commerce for our area setting up an Apprentice program. We’ve even had newspaper articles written about our successful apprentices. Each year we hire several apprentices to see how they work out, because you can never have enough good people working for you. This includes positions in sales, operations, marketing and accounting.” Tim Flynn, Allied Wire & Cable.

Fro ext m sin rud ers gle scr rea to co ew d ext y-for- mplete rusi on use line s Flynn

We haven’t had the opportunity to consider an apprenticeship program. The only reservation I would have would be the quality of the individual in the program and the required commitment on the part of the employee and the company. Knowing a program was available with prerequisites for candidates and clear obligations on the part of both parties would help to convince us to participate. Brian Burr, Sumiden Wire Products Corporation.

SIEBE COLOR MATCH

We have used internships for several roles with much success. We have never used an apprenticeship for any of our manufacturing roles, but would certainly be interested if the opportunity presented itself. Ted Bill, Pelican Wire.

Highly desirable, considering best approaches to integrating with overall development program. Christi Smiley, Insteel Industries, Inc.

MAY 2017 | 39

26% Gen Z

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Communication Is King

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“co-workers who like to collaborate” was a top factor in helping them do their best work

FEATURE

39% 39% Staffing concerns: a generational issue for the times (and letters)

Z Millennials A 2014 report by Randstad, a global supplier of HR services, and Future Workplace,Gen an HR executive network and “in person” is the most effective method Gen YZand and research firm, on Millennials (aka Generation GenMillennial Z) benchmarked the unique traits and workplace values of the communication Diverse next generations of talent. A 2016 update,Workers Gen Z andValue Millenials collide at work, offersoffurther “Y” and “Z” understandings. Below are excerpts from the report. Workplaces For more, go to www.randstad.com.

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Pa port, 37% be magnified (by) Gen Z. el Trav 32% Gen Z • Our global study found more evidence that the annual M illennials 3%Millennial and Gen Z turnaspire to be • Arguably, the culprit of2high a lead performance review is coming to an end as Gen Z and er % at 6 2 a s company th al Gallup study found start/own illenni MThe ey over isZ low engagement. same Millennials are receiving reviews either daily (19%), Gen untries and behaviorally connectco o thatan84% were not emotionally tw in k weekly (24%) or pl to wor ed to their jobs and companies. regularly (23%) 16% Gen Z and 9% 1 s al ni instead of annually Millennia Millen • IfGtechnology coursed ls Have P Z assport, en 46 percent of Gen Z say W (3%). s ill ie tr un co e re th through the veins in k T r or avel their biggest financial plan to w of Millennials, then concern is student debt.10 • Stress is the bigThe cost of a college technology can be 26% gest obstacle that 23% degree has increased Gen Z considered Gen Z’s could get in the 1,120% in the last M illennials pl an to work in sixth sense. Any two countrie 35 years.11 way of work pers organization seeking formance for both 1 9 % to recruit, engage and retain these gener16% generations (37% Gen Z ations will be hard-pressed if they aren’t M illennials for Gen Z; 39% plan to work in three coun incorporating emerging social and digital tries for Millennials). technologies into the workplace. But it’s The American not as easy as simply providing access to these tools: Psychological Association reports that these generations also struggle to rein in the distractions Millennials experience more stress and are less able to of such technologies. manage it than any other generation. Gen Z, may not be faring much better as they graduate with skyrocketing • With newly appointed management roles comes mayhem student debt and a rocky labor market. In fact, more than for many Millennials. Our study has exposed a serious half of Gen Z are either somewhat or very worried about crisis among Millennial managers, many of whom are the future (58%). simply not prepared or equipped with the EQ (emotional quotient) and people skills required to effectively manage • Gallup estimates that Millennial turnover costs the U.S. a team. economy $30.5 billion annually.

40 | WIRE JOURNAL INTERNATIONAL

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Drawing more with less!

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FEATURE

Apprenticeship program provides venue for future key employees In September 2016, NIMS was selected by the U.S. Department of Labor ( DoL) as an industry intermediary to support the expansion of registered apprenticeship (RA) within manufacturing. As part of this initiative, $500,000 is available to support companies in manufacturing in offsetting the educational costs of a DoL registered apprenticeship program. Below, NIMS Director of Strategy & Outreach Christine Hubley discusses the program.

WJI: Apprenticeship programs sound potentially interesting, but most of the positions in a typical wire and cable operation don’t seem like an easy fit into a formal program: what’s your take?

Hubley: I’m glad you asked. Part of our job is to communicate the flexibility and range of occupations that can be designed as a registered apprenticeship program.

To that end, it’s important for us to explain the benefits to various organizations in manufacturing. A registered program is intended to be a win-win deal. It helps a manufacturer gain a valuable employee, and the participant gains in-demand training while earning a wage. At the conclusion of the program, the apprentice earns an industry-recognized DoL credential. Another great practice is the inclusion of occupational specific industry-recognized credentials. Some programs may be easier to fit in some sectors than others, but that doesn’t mean they can’t be done for your sector.

to become part of a federal program, but when you understand how it works, you’ll see that this is not a paperwork nightmare. We can provide help in structuring an apprenticeship program and supporting you in determining the best partners for offering things such as the job-related education.

Hubley WJI: How much actual paperwork and reporting does an employer have to do?

Hubley: The sponsoring organization (college, employer, trade association, etc.) is required to track details about the apprentice and the hours and types of training each one gets. This information is needed to make sure the apprentice completes the program in accordance with the standards established by the sponsor. This also allows DoL to award the apprentice an industry certification at the completion of the program. In terms of actual hours, once it is understood the reporting should only take a few minutes a week. This can easily be incorporated into a organizations current employee NIMS partners with manufacturers in a wide range of skills. time sheet reporting system.

WJI: What specifically does a typical apprenticeship program entail?

Hubley: The length of an apprenticeship program depends on the complexity of the occupation and the type of program. It can be time-based, competency-based or hybrid.

The job-related education is also flexible and either woven throughout the program or front-loaded.

Apprenticeship programs range from one year to six years. During that time, the apprentice receives both structured, on-the-job training (OJT) and job-related education. For each year of the apprenticeship, the apprentice will receive normally 2,000 hours of on-the-job training and a recommended minimum of 144 hours of job-related education.

WJI: The concept is interesting, but most of the positions in a typical wire and cable operation don’t seem like an easy fit into such a formal program, such as a journeyman becoming a plumber or carpenter: can this program work for the wire and cable field? If so, how could a company prepare a formal program to meet the requirements?

Hubley: In terms of this being a formal program, yes, it is, and we understand that not everybody is anxious

42 | WIRE JOURNAL INTERNATIONAL

WJI: Why should a company want to go to all that effort?

Hubley: It might help to think of this from a different perspective. Consider the amount of time companies spend on hiring and recruiting skilled workers. What if they used those same resources and instead invested in an apprenticeship program? A “grow your own” program.

Working with a college in their community, they could build out the training that aligns with company needs and by registering have access to the $1,500 in apprentice funds as well as possible Workforce Innovation and Opportunity Act (WIOA) funds. For employers in some states, they may also have access to tuition and tax credits. As more skilled workers retire, companies should consider innovative ways to solve their skills gap and building future leaders.

WJI: If a company submits an application, is it automatically a “go” if it is an approved category, or is it then placed in a pool of candidates from which it may or may not be chosen?

Hubley: From our experience, all programs that we supported in the registration process to date have been approved.

WJI: How are applications considered? Is manufacturing competing with the service sector for the available funds?

Hubley: If your question is in reference to the $1,500/apprentice ($50,000 total/program) funds available through NIMS’ contract with DoL, these funds are allocated for occupations within manufacturing.

DoL has contracts with industry intermediaries from various sectors which also include similar incentive funds. In total, DoL has invested $90 Million to support the growth of apprenticeship within the nation.

WJI: Is there a “start” and “finish” time to this program, or is it meant to be ongoing?

Hubley: If you are referencing the incentive funds available through the NIMS contract with DoL, these funds are available through September 2017.

WJI: Who should a company contact for more details?

Hubley: For organizations interested in learning more about apprenticeships, please contact the NIMS team at apprenticeship@nims-skills.org or visit us at www.mfgapprenticeship.com.

What is NIMS? NIMS, the National Institute for Metalworking Skills, develops skills standards and credentials for careers in advanced manufacturing including the areas of machining, metalforming, industrial maintenance, and Computer Aided-Manufacturing. NIMS also develops innovative training solutions, such as competency-based apprenticeships that directly connect employers to the skilled individuals they need. It has a stakeholder base of more than 6,000 manufacturing companies. www.nims-skills.org.

Apprenticeship Opportunities Below are some of the more than thousand existing DoL apprentice categories that already exist. More can be created.

51-9061.00 17-3023.01 17-3013.00 51-4111.00 49-2092.00 17-3023.01 51-4021.00 51-2041.00 51-4022.00 17-3027.00 51-4191.00 27-1021.00 17-3026.00 49-9041.00 49-9041.00 49-9071.00 17-3029.09 13-1041.04 51-9061.00 51-6063.00 17-3029.00 19-4031.00 19-4031.00 51-2031.00 51-2031.00 51-4081.00 49-9041.00 49-9041.00 51-4081.00 51-4041.00 49-9041.00 49-9071.00 51-4041.00 17-2131.00 17-3027.00 51-2041.00 51-9021.00 51-4035.00 51-4199.00 51-4022.00 17-3029.00 17-3029.00 51-4011.00 51-9021.00 51-4111.00 51-9199.00 47-2111.00 49-9041.00 51-2092.00 15-1131.00 13-1041.04

Cable Tester (Tel & Tel) Calibration Laboratory Technician Die Designer Die Maker, Wire Drawing Electric Motor Repairer Electronics Technician Extruder Operator (Plastics) Fabricator-Assembler Metal Prod Fastener Technologist Heat Transfer Technician Heat Treater I Industrial Designer Industrial Engineering Technician Industrial Machinist System Technician Industrial Maintenance Mechanic Industrial Maintenance Repairer Industrial Manufacturing Technician Inspector, Quality Assurance Inspector, Set-Up & Lay-Out Knitter Mechanic Laboratory Asst, Metallurgical Laboratory Technician Laboratory Tester Machine Assembler Machine Builder Machine Operator I Machine Repairer Machine Repairer, Maintenance Machine Setter (Mach Shop) Machinist Maintenance Mechanic (Any Ind) Maintenance Repairer, Industrial Maintenance Machinist Materials Engineer Mechanical Engineering Technician Metal Fabricator Miller, Wet Process Milling Machine Set-Up Operator Multi Operation Form Machinist Setter Multi-Operation-Machine Operator Non-Dest Test/Eddy Current Tech (Level 1) Non-Destructive Tester Numerical Control Machinist Oper Plant Operator Plastic Tool Maker Plastics Fabricator Production Machinery Electrician (Existing Production Machinery Mechanic Production Technologist Programmer, Engineer & Scientific Quality Assurance Inspector

(Continued on next page)

MAY 2017 | 43

FEATURE

WJI: There were dozens of apprentice categories in the approved list that could be considered wire and cable: if there is a position a company would be interested in that does not currently exist, how hard is it to get that on the approved list?

Hubley: If a company is interested in adding a new occupation within manufacturing, NIMS is interested in supporting them in that process. There are well more than a thousand already, and if an employer can spell out the needs for what it is they are looking for, it indeed is feasible to have one created that works.

FEATURE

Yes, a manufacturer can create a structured apprenticeship program One company that has fielded an apprenticeship program is Southwire, which has started one for maintenance. A full report on that program, including an assessment of the activity to date and comments from a few of the participants, will be included in WJI’s November feature on plant maintenance. Below, Kenneth Heifner, Southwire’s director of maintenance systems & development and one of the program’s coordinators, shares his thoughts on the program itself.

WJI: When did the concept for an apprenticeship program for maintenance begin?

Heifner: Southwire began to look for a renewable source of skilled talent a few years ago when we struggled to fill open maintenance positions within our manufacturing plants. The apprentice concept began as an organic vision to “grow our own” talent. We started by benchmarking several large companies in the Southeast that had successful maintenance apprenticeship programs. We combined things we liked into our own version for this program.

industrial maintenance classes at the Southwire Center for Manufacturing Excellence located at the West Georgia Technical College Carrollton Campus. We also work with Gadsden State Community College, which supports the apprentice program at our facility in Heflin, Alabama.

WJI: Maintenance is a very defined area: can you see this program being offered for other plant activities?

Heifner: By definition, an apprenticeship is a system for training a new generation of practitioners of a trade or profession with on-the job training and study. I can see where this approach could WJI: Did the concept work well with other change much from operations within a what was envisioned? business. As the skill Heifner: Not really. Kenneth Heifner, back row, 2nd from left, with instructors and particilevels of the general We made sure prior pants in Southwire’s first-ever maintenance apprenticeship program. public decline, we to implementation must look for better ways to attract and retain talent. An that we had the right group of people focused on develapprenticeship seems to meet that goal. oping our program. We used a focus team approach that involved representatives from maintenance management WJI: Do you expect that this program will prove to be a and support as well as human resources. We met weekly good investment for Southwire? as a team and developed the program.

Heifner: We believe that people are our greatest assets.

The investment in the apprentice program will pay off for WJI: How difficult was it to get local colleges that were years as these resources maintain and improve our manuable to take part in this? facturing plants. These future maintenance employees are Heifner: The local technical colleges have been great learning the latest technology and will immediately begin to work with. We approached them as a partner in this to make an impact. We expect the retention rate to be very program and continue to work with them as the apprenhigh. tice program progresses. Our apprentice students attend (Continued from prior page) 51-9061.00 17-3026.00 51-9061.00 47-2111.00 51-4031.00 51-4081.00 51-4081.00 51-4111.00 49-2022.00 49-2022.00 17-3021.00

Quality Control Inspector Quality Control Technician Relay Tester Residential Wireman Spring Coiling Machine Set Spring Maker Spring-Manuftrg Set-Up Technician Tap And Die Maker Technician Technician, Submarine Cable Telecommunications Technician Test Equipment Mechanic

44 | WIRE JOURNAL INTERNATIONAL

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Tool & Die Making (Inspec, Set Up & Lay-Out) Tool And Die Maker (Die Manufacturer) Tool Builder Tool Design Tool Grinder Operator Tool Machine Set-Up Operator Tool Maker Tool Maker, Bench Tool Programmer, Numerical Welder, Arc Welder, Combination Wire Weaver, Cloth

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FEATURE

Perspectives: the role of personnel This occasional series presents a Q&A on the role of professional development with industry veteran Richard Carr, a senior vice president at Southwire Co. He was a co-founder and past president of Copperfield, LLC, which in 2007 was sold to Coleman Cable, a business of Southwire. Below, he shares his thoughts with WJI.

Bob Koslowski, Chet Dekko, WJI: Looking back over your career, did any formal Dave Chillets, Richard Miller, “professional development” programs exist in your Emil Evonovich, Jim Pomeroy, earlier years, or was it just something that one was just and Mike Frigo. In addition to expected to acquire on the job or by asking suppliers?

Carr that I was able to learn a great Carr: Yes. I was very fortunate that when I first got into deal from our vendors, Rob and Phil Kemper (Owl Wire), the industry, the company I worked for exposed me to Todd Eagan (PVC Compounders), Gary Kantz (Esteves), professional development through classes at Notre Dame John and Ray Hovey (Viteck) and Bernd Lohmuller and the American Management Association (AMA). I (Niehoff). There were many more vendors. I would ask also had the good fortune of working for, or around, some lots of questions and then listen. And finally, I empowof the greatest leaders our industry has seen. You’re lucky ered our employees and listened to their needs. if you get that kind of exposure, but you need to realize you are in the presence of WJI: Technology always greatness and do everyadvances, and it may be thing you can to learn. human nature to look Note that I said “learn,” not at past periods as being “copy.” You need to devel“lacking”: but if manuop your own style. Since facturers (as long as they I am driven by perfection, have the resources) can I have always studied my all buy the latest/greatest trade, interviewing and technology, what separates listening to anyone willthem from their peers, and ing to share knowledge, to what degree can one reading anything I can get train staff to be the best at my hands on and finally, what they do? listening to our employCarr: My personal phiees. During my early losophy on this subject Copperfield years, when is that you need to stay we were trying to grow current with technology and survive, professional and you should try to development was a little standardize wherever you more difficult. Still, we can. Yes, we all can buy were able to find time for the same machines and continued training. I would equipment. The magic is grade myself a C during in the way you use them. those years, and if I had it That can get very comdo over again would have plex, from scheduling to spent much more time, preventive maintenance to effort and resources on the team you have using Professional Development. the equipment. The magic Southwire does an excelOne does not have to look far to find the words that describe for me has always been lent job in this area.

Richard Carr’s focus. Photo courtesy of Southwire. our employees: finding the right people and allowing WJI: How did you learn them to succeed. You need what you needed to know? to listen to them, support them and care about them. A Did most companies rely on one or more “gurus” who close friend and colleague of mine has a saying, “People were the master go-to guy(s)? don’t care how much you know, until they know how Carr: I have worked in the wire and cable industry for much you care.” Once your people know you are totally 44 years. During that time I have had the good fortune to committed to them, mountains can be moved. And last know, work for or learn from the best. Just to name a few,

46 | WIRE JOURNAL INTERNATIONAL

WJI: One past wild card was the introduction of multiwire drawing equipment: could what seems to be increasing emphasis on the potential for Industry 4.0/ Smart Factory pose a different yet significant challenge for manufacturers to account for? Could this become an added “education” element?

Carr: This is exactly why I love this industry, and why you must always think that there is a better and faster way to do every task. Bob Knight, the legendary college basketball coach, would talk about beating the game. This meant that every shot was made, every defensive effort kept the other team from scoring and so on. He wasn’t trying to beat the opponent, he was trying to beat the game. He was trying to achieve perfection. Industry 4.0 is another tool and technology that helps us to continue to improve on everything we do. As our industry continues advancing technologically it will require our talent to improve as well.

WJI: What does a plant manager have to be able to do to get the most out of a given company operation? Is the human element as important as ever, or in an electronic era where equipment is designed to be “idiot proof” is it actually less of a factor?

Carr: You can look at almost any entity—a business, a sports franchise and even a church—and what you will find at the bottom of every success story is the leader. So for a successful manufacturing operation, you bet your life the manager is critical. To be successful, you need to have both a high intellectual and emotional IQ, be able to stay on top of all facets of the business, be a leader, a mentor, a coach, a motivator, a salesman and, last but not least, a good listener. I would not characterize manufacturing wire as idiot proof just yet. As we continue implementing continuous improvement tools and technology advances, I can see us getting closer to that, but for now we continue to rely very heavily on our people talent and their ability to get and stay engaged. That is why a plant manager’s job is so important.

WJI: Can all the answers be found in pursuing Lean manufacturing and other such programs? If not, what makes the difference?

Carr: When we started Copperfield in 1990, my dream and vision was that we wanted to build a company that focused on two very important components. I called these our “Two Kings.” One was the customer and the other was the production employee. I have been doing this for 44 years and still struggle with an appropriate title for our production employees. We have called them production

associates, production engineers and other titles, but none of those titles seem to me to fully identify how important this group is to any company’s success. Back to the Two Kings, if you are not one of the Kings, what you are is overhead, a servant to the Two Kings. Your job is to eliminate hurdles so the Kings can succeed. This can be a difficult assignment. Many people don’t like being a servant. I loved being the servant; the harder I had to work for the Kings, the better our company performed. Back to LEAN, I also wanted a facility that was different from the typical wire and cable facility in the 90s. It needed to be clean, floors epoxy-coated, a standardized paint scheme for all plants and equipment, everything neat and orderly, with the least amount of resources required to get the job done as it related to man, material and machine. We were actually practicing LEAN back then without knowing it. It wasn’t until 2007, that I was officially introduced to LEAN. I am a disciple of this philosophy. It is valu-

“Giving back” via Southwire’s Project Gift, packing boxes with essentials for military serving abroad. able, but it is also very difficult to implement because of human nature. Many people like to do things their way, and that does not work well when implementing LEAN. It gives you a set of tools to help you identify and solve problems. The more problems you solve, the closer to perfection you get, and that is a good thing. I believe that Copperfield has played a key role in getting our industry to think differently about manufacturing and how it looks.

I have seen many changes to our industry in the last 27 years. Most of them good.

WJI: And other thoughts?

Carr: We need to anticipate and listen to our customer’s (King’s) needs, and then make it even easier for them to do business with us. We also have to make our employees feel that what they do is important, because it is vital.

To be successful at that, we need to focus on both the big things and little things, because both matter.

Perspectives is an occasional section to present notable information about subjects that may be directly or indirectly related to the wire and cable industry. If your company would like to contribute a presentation, send an e-mail explaining what it would be about to editorial@wirenet.org.

MAY 2017 | 47

FEATURE

but not least, you must always be willing to raise the bar.

We must practice continuous improvement.

N

FERROUS

WIRE HANDBOOK

EDITED

BY

ROBERT M. SHEMENSKI, PH.D.

THE WIRE ASSOCIATION INTERNATIONAL, INC. 48 | WIRE JOURNAL INTERNATIONAL

ISBN 1-877836-26-5 ISBN 1-877836-26-5 978-1-877836-26-8 978-1-877836-26-8

FERROUS FERROUS

WIRE WIRE HANDBOOK HANDBOOK

The most recent The most recentinina aseries series of of handbooks published handbooks publishedbyby The Wire Association The Wire AssociationInternational, International,Inc., Inc., thethe Ferrous Wire Handbook Ferrous Wire Handbookis ispresented presented as as a modern-day reference a modern-day referencetool toolfor forthose those working directly in the steel wire working directly in the steel wire manufacturing, manufacturing,engineering, engineering,oror operations sectors operations sectorsofofthe theindustry. industry.

This volume covers This volume coversa abroad broadrange range of of topics to to illustrate topics illustrateequipment equipmenttypes, types, processes, and specialtyapplications applicationsthat that processes, and specialty being used throughoutthe theworld world areare being used throughout manufacturesteel steelwire. wire. to to manufacture

Published by Published by THE WIRE ASSOCIATION INTERNATIONAL, INC. THE WIRE ASSOCIATION INTERNATIONAL, INC. Guilford, Connecticut, USA Guilford, Connecticut, USA

Reintroducing a timeless steel industry primer The importance of cutting-edge technology for industry is understood, but for the steel sector, behind the “latest and greatest” is decades and decades of industry basics and wisdom that continue to be of much value.

The WAI’s Ferrous Wire Handbook, published in 2008, may well be the most exhaustively comprehensive wealth of information about steel and steel alloy wire production.

Edited by Dr. Robert Shemenski, with contributions from dozens of industry experts, the 1,162 pages collectively represent the ultimate steel industry resource.

The Association is now reintroducing this book to the industry. This section includes the Table of Contents and the first chapter, “A Short History of the Ferrous Wire Industry,” which presents the big picture of how the industry developed, akin to the rings of trees.

The chapters that follow present the advent of different technology, theory, key product sectors types and useful process theory and information, and more.

Every ferrous company should have a copy of the Ferrous Wire Handbook, and to make that decision a bit easier to make, the WAI is offering the book ($235/$195 for WAI members) at 20% off for any order made by the end of July.

Want to see more? You can ask for a free PDF of chapters 2 and 3. To ask for the PDF or to order a copy of the book, contact Marc Murray at mmurray@wirenet.org. Individual chapters can also be bought for $25 each.

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TABLE OF CONTENTS Chapters 1

A Short History of the Ferrous Wire Industry . . . . . . . . . 1

2

Evolution of Modern Steel Manufacture . . . . . . . . . . . . . . 9

3

Modern Steel Manufacturing . . . . . . . . . . . . . . . . . . . . . . 23

4

Continuous Casting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

5

Wire Rod Production . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

6

Controlled Cooling of Wire Rod . . . . . . . . . . . . . . . . . . . 83

7

The Modern Morgan High-Speed Rod Mill . . . . . . . . . 107

8

Rod Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

9

Pickling and Coating . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

10

Mechanical Descaling of Wire Rod . . . . . . . . . . . . . . . . 225

11

Deformation in Cold Drawing . . . . . . . . . . . . . . . . . . . . 271

12

Theory of Wiredrawing . . . . . . . . . . . . . . . . . . . . . . . . . 299

13

Wiredrawing Machinery . . . . . . . . . . . . . . . . . . . . . . . . 327

14

Wiredrawing Dies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389

15

Finishing Equipment for Drawing Dies . . . . . . . . . . . . 423

16

Lubrication in Ferrous Wiredrawing . . . . . . . . . . . . . . . 445

17

Heat Treatment of Ferrous Wire . . . . . . . . . . . . . . . . . . 461

18

Stress Relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471

19

Annealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483

20

Oil Tempering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 505

21

Patenting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521

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22

Fluidized Bed Heat Treatment . . . . . . . . . . . . . . . . . . . . 579

23

Corrosion of Steel and Its Protective Coating . . . . . . . . 607

24

Galvanizing and Other Coatings . . . . . . . . . . . . . . . . . . 685

25

Straightening and Cutting Wire . . . . . . . . . . . . . . . . . . . 741

26

Testing Ferrous Rod or Wire . . . . . . . . . . . . . . . . . . . . . 769

27

Statistical Process Control as a Shop Floor Problem-Solving Tool . . . . . . . . . . . . . . . . . . . . . . 803

28

Rolling Flat and Shaped Wire . . . . . . . . . . . . . . . . . . . . 811

29

Plastic Coating Steel Wire . . . . . . . . . . . . . . . . . . . . . . . 863

30

Wire Strand and Wire Rope . . . . . . . . . . . . . . . . . . . . . . 913

31

Bridge Wire, Bridge Strand, and Bridge Rope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 929

32

Nails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 953

33

Barbed Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 963

34

Forming and Bending . . . . . . . . . . . . . . . . . . . . . . . . . . . 975

35

Mechanical Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . 1025

36

Steel Wire for Rubber Reinforcement . . . . . . . . . . . . . 1045

Appendices I

Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1103

II

Commonly Used Standard Wire Gauge Designations . . . . . . . . . . . . . . . . . . . . . . . 1107

III

Nomographs for Calculation of Iron Content in Acid Baths . . . . . . . . . . . . . . . . . . . 1111

IV

Temperature Conversion Tablesâ&#x20AC;&#x201D; Fahrenheit, Celsius . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1115

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Chapter 1

A SHORT HISTORY OF THE FERROUS WIRE INDUSTRY Nonferrous Wire Making in Ancient Times Wire can be called a ubiquitous product because its usefulness is not immediately perceptible in contrast to heavy metal products such as structural beams, railroad rails, and large castings. Because it is inconspicuous, its important contribution to our modern civilization is often overlooked. Without wire, however, many of the extremely noteworthy and most commonly accepted accomplishments of todayâ&#x20AC;&#x201D;from space vehicles, to electric guitars, to the springs in ballpoint pens, to surgical implantsâ&#x20AC;&#x201D;would not be possible.

Archaeological evidence confirms that metallic wire was used for thousands of years. Gold wire has been found with the entombed adornments of ancient Egyptian mummies and in the graves of the Chibchu culture of Peru. Such wire was probably made by hammering and folding ductile metal sheets, then pulling the folded forms through drilled holes to create a round, compacted, cross section. The Book of Exodus, one of the oldest literary works in the Western realm of knowledge, contains a description of exactly such activity.

Household items made of copper and silver wire surviving from 2800 B.C. have been excavated from Neolithic graves in the vicinity of Remendello, Italy.

The wiredrawing process, which is the most distinctive characteristic of the wire industry, is mentioned in Roman archives dating from A.D. 400. Although drawing dies of great antiquity have been unearthed at several places, the earliest reliable written description of the wiredrawing process is given by Theophilus Presbyter (A.D. 10701

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1125) who described: “irons, three fingers wide, narrow at the ends, rather thin, pierced with three or four rows of holes through which the wires are drawn.”

The laborious manufacturing technique of beating ductile metal from ingot into a sheet, then cutting it into strips, and finally drawing the strips into wire, limited the application of metallic wire to luxury items. Mention of wiredrawing dies becomes quite frequent from the 12th century onward in Europe. By that time there was a clear task distinction between the smith who fashioned wire by beating it with hammer and anvil and the wiredrawer who used a wortle or drawplate to reduce it to size. The village of Altena, Germany, was a center for wire production in these early times. An historical museum there traces the evolution of wiremaking from medieval chain mail to modern wire products.

Craftsmen known as “wiredrawers” were well established in Paris by the 13th century. A Parisian craft document dated A.D. 1270 reads: “1. The wire drawer must thoroughly understand his trade and have sufficient capital at his command.

2. The wire drawer may have as many apprentices and servants as he wishes and may work nights as much as he pleases.

3. The wire drawer needs pay no taxes on anything related to his trade, which he buys or sells in Paris.

4. Apprentices to wire drawers will serve ten years without pay and then be paid a premium of twenty sous.”

Evidently, these rules were part of an agreement signed by the municipality and the Wire Drawers Guild for mutual interest and benefit.

Several very old uses for ferrous or brass wire, for which only very short lengths were needed, have survived until the present time.

Two examples of this are the needle and pin industry and the ornamental product known as leonic wire (braided and spun wire yarns or tinsel used to decorate costumes). Detailed records of the evolution of the leonic wire industry dating back to the 1500s have been retained. The trade of the wiredrawer was common enough by the Middle Ages that a surviving alphabet book of printed documents references the drawing of wire as a recognizable task when explaining the letter “D.” The advent of mechanical wiredrawing is usually credited to Rudolph of Nuremberg about the year 1350. He introduced water2

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CHAPTER 1 — A SHORT HISTORY OF THE FERROUS WIRE INDUSTRY powered drawing machinery, which marked the first of many laborsaving, cost-reducing devices that lowered the price of the product and stimulated additional uses for iron and brass wire. Of these new uses, the most important was the application of short wire teeth for the combing cards used to prepare fibers for textile spinning. The growth of the woolen industry encouraged the production of card wire in such wool-producing areas as Yorkshire, which has the largest concentration of wiredrawing plants in England today.

The year 1564 was particularly notable in the history of ferrous wiremaking because that year a group of wiredrawers from Saxony were invited by Queen Elizabeth I to settle at Tintern, Monmouthshire, Wales. These German craftsmen built a water-powered works, and, by reason of their skill and knowledge of the best German practices, established a prosperous industry within a relatively short period of time. The early protectionist practices of King Edward IV safeguarded the wire industry in England and the erection of the Tintern Wire Works had two far-reaching effects for the wire industry in the United Kingdom. First, the owners of the plant were granted an exclusive monopoly for the manufacture of iron and brass wire. Second, waterpower was applied to the wiredrawing process for the first time in England. Waterwheels drove all of the iron forging equipment, and the use of such machinery was included in the monopoly. Thus, a greater variety and improved quality of wire were made available for consumption almost immediately.

Prior to the Tintern Works, all English wire was drawn by hand using a device called brackes or brakes. This device is believed to have been a hand lever that was mounted on a bench from which the terms “drawing bench” and “breaking down” were derived and continue to be used today. The brakeman passed his product onward to another worker called girdleman, who performed further size reduction. Men who were harnessed into a seat mounted as a swing drew the wire. By taking hold of the wire and using tongs with pincers fitted to the drawing holes that were fastened to a girdle around their body, they extended their legs by pushing their feet against a stump and pulled the wire through the hole. The swing mount allowed them to release their grip and slide the tongs forward for the next pull. Then another wiredrawer, using a crank mounted on a wooden block, reduced the wire from the size produced by the girdlemen to the finer diameters of card wire.

3

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The wiredrawing block that was well known and used in the 1600s can be seen in many medieval illustrations, including sketches made by Leonardo da Vinci. As long as wire was drawn by manpower, the coils or bundles sold to the trade were small. Because long lengths of rod to start the process were not available at that time, it was difficult to draw a long, continuous length of wire.

In the Bristol area of England, many laws were enacted to protect wiredrawers. Admission to an apprenticeship required that the applicant be free born and to not have been in conflict with the laws of the country. Apprenticeship was for a period of seven years. At the end of that time, the apprentice could become a master immediately or after a few years of working for wages as a journeyman under a master. Guilds protected members from outside competition.

Drawing card wire and making cards were exclusively restricted to members of the guilds and their employees. Wardens were elected who administered the guild and supervised the acceptability of wire goods being manufactured. They were authorized to search for defective material, which constituted the earliest quality control and inspection program.

Technology Transfer in the Art of Rod Rolling The world’s total annual production of wire remained relatively small until new methods of rod rolling were conceived. The notion of a rod as a long piece of stiff metal, which was handled as a straight length or sometimes doubled back upon itself, was acknowledged as the starting point for the drawing of wire. Wrought iron exhibits this quality of stiffness to a diameter of approximately 3/8 in. (9.5 mm).

Skilled smiths made the original form of the rod, known as a “hammered rod,” by holding one end of the rod while a water-driven hammer applied to the other heated end lengthened it. This progressive hammering technique required constant reheating to achieve diameter reduction and depended entirely upon the rigidity of the metal for control by the workman.

The first step toward creating a longer length of rod, known as a “slit rod,” was produced by flattening a plate of metal in a two-high roll stand with two simple plain flat rolls. The the plates were subdivided into narrow strips in a two-high mill by other rolls equipped with collars and grooves. This kind of mill was commonly used in Europe by 1683. Christopher Polhem in Sweden is believed to have been the first to attempt to reduce rods directly by passing heated bil4

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CHAPTER 1 — A SHORT HISTORY OF THE FERROUS WIRE INDUSTRY lets, without flattening, through a sequence of smaller and smaller grooves in matched two-high rolls; however, his efforts did not meet with total success.

The raw iron used in the Tintern mill was known as “Osmond Iron,” a superior grade of wrought iron melted at the works with a special grade of charcoal. By 1800 Osmond Iron had been replaced in England by puddled iron as a raw material. Historians usually credit Henry Cort of Fareham, near Portsmouth, with inventing the puddling process in 1783 when he obtained a patent. In addition, the invention also is credited to a Welsh ironworks foreman named Peter Onions. Henry Cort’s contribution is notable because it is linked to his simultaneous combination of puddling the iron in batches with the application of grooved rolls for rod rolling. Cort launched the modern era of rod rolling.

The Cort mill’s product was rather poor by today’s standards— not more than 16.4 ft. (5 m) in a straight length and only on rare occasions rolled smaller than 0.51 in. (13 mm) diameter. However, it was produced much more cheaply than rods made by the earlier methods that it quickly dominated the marketplace. This rod diameter also became the starting point of the gauge numbers used for sizing wire, “zero” or “ought” gauge being the smallest diameter that could be hot rolled. Higher numbers of the gauging system originally represented the number of times rolled rod had been repeatedly cold drawn to a smaller size.

Between 1812 and 1860 many inventions requiring iron wire were devised in Europe and America which created greater demands for the product than ever before in history. Although card wire continued as the dominant product for many decades, each year new applications enlarged the market. Wire suspension bridges appeared in 1816, wire ship rigging in 1829, wire ropes, cables, and rivets in 1834, the electric telegraph in 1840, and crinoline skirts for ladies’ apparel in 1850. The iron wire telegraph, in particular, emphasized the need for longer and longer lengths of wire without splices, which in turn fostered new studies of how to roll rods in longer pieces. At the time the first wire telegraph systems were being tested, a typical iron rod that was available in the marketplace weighed only about 15 lbs.

Periodic unavailability of English wire in the timeframe preceding the American Revolution caused the sporadic growth of a wire industry in the North American colonies. These undertakings usually died out very quickly when English wire could be obtained again.

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Card wire was an early requirement for an infant textile industry, but prior to 1800 there was little or no tariff protection for wiremakers in America and President Thomas Jeffersonâ&#x20AC;&#x2122;s punitive embargoes against imported goods actually had a negative impact. This situation changed very rapidly during the War of 1812 when more permanent installations arose. For example, a cottage wire industry was then set up in Spencer, Massachusetts, by Charles Watson and Windsor Hatch that survived until the post-World War II era. The company name evolved into Wickwire-Spencer, and afterward it was acquired

by Colorado Fuel & Iron and became CFI Steel Corporation. Longlived wire company survivals became increasingly rare in Europe and America after 1960 when favorable currency exchange rates and propitious labor availability created a climate for technology transfer to Pacific Rim nations such as Japan, Korea, and China.

Global Advancements in Rod Rolling and Wiredrawing The most significant impetus given to the North American wire industry after 1812 was the advent of anthracite coal mining and iron smelting in Pennsylvania. This cheap, readily available energy source coupled with adequate availability of high quality iron ore, stimulated a vast expansion of American ironworking after 1840, particularly for the production of railroad rails. The demand for rails, in turn, provided incentive to find ways to accelerate all of the metal rolling processes.

Around 1860 a new type of rod mill, known as a Belgian mill, was introduced in Europe. Separating the roughing section from the finishing section allowed for increased speed of the finishing rolls.

This kind of mill was modified to introduce the concept known as looping. It was discovered that enough heat could be retained in the rod so that when it had been reduced to a suitable cross section, the front end could be caught with tongs by a workman who swung it around 180 degrees into the next pass in rolls facing the opposite direction. This permitted rods 91 ft. (300 m) long and weighing 50 lbs. to be rolled. The maximum rolling speed was limited only by the ability of the catchers to seize rods at speeds up to about 300 m per minute.

In Manchester, England, the limitation of rolling speed was studied and overcome by George Bedson, an employee of Richard Johnson & Nephew. In 1862 Bedson installed a new rod mill with rolls arranged in continuous sequence, thus eliminating back-and6

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CHAPTER 1 — A SHORT HISTORY OF THE FERROUS WIRE INDUSTRY forth rolling. This was probably one of the most momentous developments in the history of the trade, as the new mill was able to produce rod coils weighing 100 lbs. (45 kg) or more. The Washburn & Moen firm, Worcester, Massachusetts, installed a Bedson rod mill in 1869 and quickly advanced to become the foremost wiremaker in North America. In Worcester a mill superintendent named Charles Morgan noted some opportunities for improvements in the design.

He innovated horizontal rolls equipped with twist guides that turned the metal suitably between each pass. His mill, which was running in 1878, then had the advantage of being able to roll two rods side by side, a feature unattainable in the Bedson mill.

The advances pioneered by Morgan opened a new era of rod mill improvements. By 1882 William Garrett of the Rolling Mill Company, Cleveland, Ohio, had split his employer’s Belgian mill equipment in half and was driving both halves separately at different speeds. Garrett was the first to feed two rods into finishing rolls simultaneously. With other improvements, principally the application of twisting guides and the concept of intermediate stands between roughing and finishing rolls, he was able to use a much larger billet, increasing the size of his rolled rod bundles to 150 lbs. (68 kg). The advent of longer and heavier rod coils set the stage for the development of continuous wiredrawing machinery.

In the 1870s several inventors in Germany, England, and America developed multiple block machines. This coincided with the arrival of the new, cheaper pneumatic steel, circa 1860, which quickly displaced wrought iron as the metal of choice.

Simultaneously, James Horsfall and William Smith discovered the tempering process known as “patenting” that allowed significant increases in wire tensile strength. The stage was set for lower costs by making larger and larger unit packages of wire.

Exploitation of the new drawing equipment continued to be restricted, however, by the limited life of die plates. Therefore it was inevitable that a wiredrawing die would be produced which could withstand high speed and provide long wear. The Osram Company, a Krupp affiliate, was a mass producer of electric lamp filaments and they developed a process of mixing tungsten carbide particles in a matrix and then sintering the entire composite. In 1925 drawing dies employed the resulting product known as “Widia” (Diamond-like) in America. By 1929 Union Wire Die Company, Firth Sterling, and General Electric were producing tungsten carbide dies. Drawing dies 7

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were now capable of producing many times the previous quantity of wire on gauge and through a single hole; consequently, continuous wiredrawing machines became popular and have improved ever since.

Bibliography Bullock, Frank. “The Story of Wire—II,” Wire & Wire Products, pp. 97–104, March 1935.

Bedson, Joseph P. “Iron and Steel Wire and the Development of Its Manufacture,” Journal of the Iron & Steel Institute, London, U.K., 1894.

Daniels, Fred. “Rod Rolling Mills and Their Development in America,” New York, Transactions, A.S.M.E., Vol. XIV, pp. 588–618, 1893.

Garrett, William. “Development of American Rod Rolling,” The Iron Age, New York, p. 15, January 2, 1896.

Hunt, Robert. “Wire Rod Rolling,” Cassier’s Engineering Illustrated,Vol. VI, pp. 249–261 May 1884.

Kuhn, Dietmar. “A Brilliant Piece of History,” Wireworld, pp. 10–14, June 1990.

Lee, B. T. “The ‘Mystere’ of Needlemaking.” Wire Industry, April-August-October 1984.

Lewis, Kenneth. Steel Wire in America, The Wire Association International, Inc., Guilford, Connecticut, 1952.

Price, W. H. The English Patents of Monopoly, Cambridge, U.K., pp. 55–60, 1906.

Ridge, I. and D. Sim. Iron for the Eagles, Gloustershire, U.K., Tempus, 2002.

Schubert, Dr. R. H. “The Wire Drawers of Bristol,” Wire Industry, pp. 659–663, October 1948.

Serini, Mino “Copper in Northern Italy,” Wireworld, pp. 64, 6–89.

Sim, D. “Roman Chain Mail—Experiments to Reproduce the Techniques of Manufacture,” Brittania, Vol. XXVII, pp. 359–371.

Smith, J. Bucknall. A Treatise Upon Wire, Wiley, New York, 1891.

Thomsen, E. G. “Early Wire Drawing Through Dies,” Transactions, ASME, pp. 1216–1221, 1974.

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PRODUCTS & MEDIA

PRODUCTS TECHNOLOGY Tandem extrusion solution combines metal-tape forming and welding Rosendahl, a global supplier of wire and cable technology, has developed a tandem solution for HV cables, a metal tape forming and welding line that employs tandem extrusion.

product diameter (40 mm to 200 mm), the line runs at speeds of up to 15 m/min. The tools are easy to change and the line’s performance can be tracked by the RIO line control system. The system reports and analyzes the process and output.

Contact: Rosendahl, www.rosendahlnextrom.com.

Cutting and feeding system makes for a more efficient process operation

A press release said that the Rosendahl RH-W system (shown) can do metal-tape forming and welding, and the subsequent jacketing process, inline in a tandem process.

Both production speed and product quality are maintained at a constant high level, allowing for high productivity as the continuous welding solution supports long product lengths and smooth production.

Aluminum, copper and stainless steel wire can be processed on the same line. It is designed to be flexible in processing different metals as well as the entire production process, as each production step can be adjusted to a manufacturer’s needs, e.g. either inline or offline, smooth or corrugated. The options are manifold. Depending on

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U.S.-based DavisStandard, LLC, offers a cutting and feeding machine that is ideal in supporting low-voltage wire and cable processes for insulating applications.

A press release said that the system, designed for efficiency, allows for timely transfers from one take-up to the other while minimizing operator involvement. This expedites the take-up reel change process during insulation and enables wire and cable manufacturers to boost output.

The machine’s deflection pulley arrangement sits between two portal take-ups. It features pulleys for round cables with integrated clamping, feeding and cutting devices. A pre-programmed length of cable can be pulled out of the accumulator enabling the operator to

PRODUCTS & MEDIA

affix the end of the cable to an empty reel after being cut.

Pneumatic clamping during take-up changeover is delivered via a helper caterpillar. The caterpillar pulls the cable from the accumulator, transferring it from one take-up to the other. Design advantages include adjustable vertical and horizontal guiding rollers at the inlet and outlet sides of the machine, and adjustable upper and lower belts on pneumatic cylinders with pressure rollers. An AC gear motor delivers power with an automatic “off” feature when the winding drives are activated.

“Like other Davis-Standard machinery, such as the Thermatic® series extruder, the cutting and feeding station is designed to be very robust to ensure longevity and allow for fast, efficient run times,” said John Zachow, vice president, Davis-Standard Wire and Cable Systems.

Contact: John Zachow, Davis-Standard, LLC, tel.

860-599-6258, jzachow@davis-standard.com, www.davis-standard.com.

Ethernet cable is 1st such one to pass key requirements for critical auto use U.S. Champlain Cable Corporation (CCC) announced that the company’s high-temperature, ruggedized ethernet cable has passed critical requirements.

A press release said that CCC has passed 1000 Base-T1 OPEN Alliance requirements for jacketed and unjacketed 0.35mm2, 125⁰C rated, twisted-pair cables. This, it said, makes it the first such commercially available 1000 Base-T1 twisted pair cable for high speed Ethernet for automotive and commercial vehicle applications. CCC has already secured approvals, worldwide, from numerous major OEM’s and Tier 1 suppliers for the company’s 100 Base-T1 Ruggedized Ethernet cables as well as approvals from several major OEMs and Tier 1 suppliers. The 125⁰C-rated ruggedized Ethernet cable can be used in high-temperature areas on vehicles previously not possible with other Ethernet cables. Test reports and samples are available upon request.

Observed Champlain Cable’s Richard Antic, “The successful testing of multiple cable lots to the 1000 Base-T1 requirements is an outstanding achievement, a stepping stone towards multi-gig cables and applications, and we are continuing to develop new higher speed, high temperature cables. We expect to have several 5gig and higher cables available in the upcoming year. In electrically noisy environments, our shielded Ethernet cables perform with excellent immunity to electrical interference.”

Contact: Champlain Cable Corporation, www.champcable.com.

MAY 2017 | 61

PRODUCTS & MEDIA

New rubber/silicone crosshead allows operators to easily make changes

Next-generation silicon alternative can be used for demanding medical uses

U.S.-based Guill Tool’s new 500 Series crosshead with mechanically assisted gum space (MAGS) adjustment system is designed specifically for the flow characteristics and unique processing challenges of elastomeric compounds.

A press release said that the new method of gum space adjustment allows the operator to make an effortless change from a single point using a common socket wrench. No more need to struggle with multiple nuts and bolts leads to faster adjustments. The visual indicator on the core tube allows the operator to see how far the gum space has been moved, making those adjustments much more accurate and repeatable.

The 500 Series’ hardware-free and patented cam lock design means that no time is wasted unbolting and re-securing fasteners for disassembly and re-assembly. Only half of a rotation of the cam nut is required to loosen and automatically extract the deflector from the head body, which is another time saver. Also, with no undercuts on the deflector, there are no material hang-ups when extracting the deflector, allowing for faster and easier cleaning and changeover.

The crosshead also has the latest center-stage concentricity adjustment system that significantly reduces pressure on the tooling, allowing easier and more precise concentricity adjustments without loosening the face bolts.

Easy-Out inserts for the adjusting bolts also allow simple replacement of locked or damaged adjusting bolts, which further saves on repair and downtime. Another innovative feature is a cast aluminum liquid-fed cooling sleeve that allows the user to switch out the cooling jacket in the event of a line obstruction, again reducing downtime compared to traditional integrated cooling systems.

The addition of a newly designed flow inlet channel reduces the shear and heat that is generated as the materials are being processed. This leads to lower head pressures allowing the material to move through the head in a much more balanced and even flow. The 500 Series crosshead with MAGS gum space adjustment is a drop-in replacement on most existing NRM lines, however this crosshead design can also be adapted to fit any extruder design or line layout.

Contact: Bill Conley, Guill Tool & Engineering, tel. 401-828-7600, sales@guill.com, www.guill.com.

Northwire reports that its recently introduced USP Class VI silicone alternative, BioCompatic, ideal for medical cable applications with stringent requirements, is free of phthalates, halogens, and latex, and compatible for steam, hydrogen peroxide, gamma and ETO sterilization.

A press release said that the new product, introduced at the MD&M West Trade Show on Feb. 7-9, offers competitive advantages to traditional silicone wire and cable, BioCompatic, a cost-effective upgrade to silicone, does not require the traditional curing process, which subsequently increases its speed to market. With elevated performance improvements over traditional silicone wire and cable, BioCompatic offers robust resistance to chemicals, cuts, and abrasion essential within stringent engineering applications.

For the second variant in this product line, Northwire responded to customer requests with a softer and smoother solution by incorporating BioCompatic II, which features a lower durometer, ensuring optimal comfort for patient and practitioner interaction. The next generation BioCompatic III, ideal for medical cable applications with stringent flex-life requirements, offers the following additional benefits: strongest generation of material in terms of crush and cut resistance; great insulation material for conductors; similar or improved dielectric strength and flexibility compared to standard olefins, fluoropolymers and silicone; UV resistance to accommodate unique applications; and a higher durometer rating (Shore Hardness “A” of 85).

Contact: Northwire, tel. 800-468-1516, cableinfo_northwire@lemo.com, www.northwire.com.

62 | WIRE JOURNAL INTERNATIONAL

Cut-and-strip system is very flexible Schleuniger, Inc., was scheduled to display a cut-andstrip machine at two different events in April.

Per the company, its newest cut and strip machine, the EcoStrip 9380, offers the most complete feature set at an economical price point. It can be configured with rollers or belt transports and the configuration can be quickly and easily changed by the operator.

The machine has a unique three-position design of the optional belt-feeding system that further enhances the customer’s capabilities. It can be set for normal mode, roller mode or short mode processing, depending upon the

Barrel packer is designed to be flexible as well as cost-effective Wire Machine Systems, Inc., reports that it is offering a rotating drum coiler, type BTWB-400, from Germany’s Hüttner Maschinenfabrik GmbH. Per the company, the barrel packer provides the industry a more flexible and cost-effective way to drum pack bare steel, alloys and nonferrous wire as well as insulated cable. The individual drive systems on the coiling capstan and drum turntable provide optimal packaging quality, with a rosette-lay pattern that meets today’s stringent quality standards and payout requirements.

The machine’s configuration provides “twist-free” packaging, making it an ideal choice for all wire and cable applications, including welding wire and certain alloys which have a very stringent no-twist requirement.

In terms of flexibility, the Hüttner drum packer can package a wide range of wire diameters as well as use various drum dimensions.

The simplicity of the machine settings makes for simple and easy operator setup, and provides process repeatability that enables a consistent quality package customers can rely on. The drum packer is also simple to load/unload and is traditionally used off-line at speeds up to 120 m/min, but can be incorporated into a drawing or insulating line if required.

Contact: Hüttner Maschinenfabrik GmbH, www.huettner-maschinen.de, Wire Machine Systems, Inc., tel. 260-483-9269, sales@wire-machine.com, www.wire-machines.com.

Silicon masterbatch was designed to boost extrusion throughput Dow Corning reports that its new MB25-502 Masterbatch, an advanced new silicone technology, is specifically designed to optimize processability of highly mineral-filled polyethylene (PE) compounds for wire and cable applications.

A press release said the new masterbatch is the first in the industry to combine best-in-class processing with an affordable cost. By reducing screw torque, die buildup and die pressure, the material can improve extrusion throughput by up to 110% compared to PE compounds without a processing additive, it said.

“The wire and cable industry is moving toward the use of halogen-free flame retardants, but these mineral additives can cause major processing issues due to the high loadings that are required for effectiveness,” said Christopher Paulo, global segment leader, Plastics & Composites for Dow Corning. “Until now, customers were forced to choose between expensive, over-engineered additives with higher performance, or low-cost

MAY 2017 | 63

PRODUCTS & MEDIA

application. The EcoStrip 9380 is also compatible with a wide range of accessories, including prefeeding, marking, stacking and coiling, which turn the stand-alone machine into a fully automatic processing line.

Schleuniger offers a range of machines for cutting, stripping and crimping all types of wire and cable, including benchtop wire models.

Contact: Schleuniger, Inc., tel. 603-668-8117, sales@schleuniger.com, www.schleuniger-na.com.

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um for unneeded functionality.”

The new masterbatch raises throughput of PE compounds with high mineral loadings (up to 70% by weight) by reducing screw torque by as much as 30%. Lower torque, in turn, accelerates production and cuts energy costs. It also avoids die build-up and die pressure that require frequent interruptions for cleaning. By narrowly targeting processability issues instead of including extra functionality, the new masterbatch achieves outstanding results at a competitive price. It is also efficient at lower loadings (0.5 to 1.0%) than competitive silicone-based additives. It is compatible with low-density PE (LDPE), linear low-density PE (LLDPE) and cross-linked PE (XLPE). It is supplied globally as free-flowing pellets.

Contact: Dow Corning, dowcorning.com.

NEMA offers new cable standards set The National Electrical Manufacturers Association (NEMA) has published a new Cable Standards Set for the wire and cable industry that includes the below standards from ANSI, NEMA and IWCEA. • 5-46 kV shielded power cable for use in the transmission and distribution of electric energy • Ampacities of cables installed in cable trays • Guide for frequency of sampling extruded dielectric power, control, instrumentation & portable cables for test • Standard for Cat. 6 and 6A, 100 Ohm, individually unshielded twisted pairs, indoor cables (with or without an overall shield) for use in LAN communication wiring systems • Portable and power feeder cables for use in mines and similar applications • Power cables rated 2,000 V or less for the distribution of electrical energy • Standard for control, thermocouple extension, and instrumentation cables • Standard for nonshielded cables rated 2001-5000 V for use in the distribution of electric energy • and Standard test methods for extruded dielectric power, control, instrumentation, and portable cables for test The Cable Standards Set is available for $999 in hard copy and can be accessed as an electronic download at the NEMA website.

Contact: NEMA, www.nema.org.

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MAY 2017 | 65

PRODUCTS & MEDIA

but underperforming products.

(Our new) masterbatch enables wire and cable customers to maximize productivity without paying a premi-

PATENTS

Patent Update (Contâ&#x20AC;&#x2122;d. from p. 21)

Composite cable U.S. Patent No.: 9,606,312 Patent date: March 28, 2017 Filed: March 8, 2012 Assignee: Molex, LLC, USA Inventors: Masako Nishikawa, Akihiro Shimotsu A planar optical waveguide part that includes an optical waveguide, a planar conductive wire part that includes a conductive wire, and a connecting end part formed on the lengthwise direction end part, wherein the connecting end part is provided with an optical waveguide end part formed on the lengthwise direction end part of the conductive wire part, a conductive end part formed on the lengthwise direction end part of the conductive wire part, and an intermediate plate intervening between the optical waveguide end part and the conductive end part; the optical waveguide end part, conductive end part, and intermediate plate are bonded by layering; and a bonding pad where components are bonded is formed by ultrasonic bonding to the top surface of the conductive end part.

Hybrid elastic cable and process for manufacturing such a cable U.S. Patent No.: 9,605,362 Patent date: March 28, 2017 Filed: Jan. 24, 2013 Assignee: CALYF Maisons Laffitte, France Inventor: Francis Cour Hybrid elastic cable comprising at least one elastic filament yarn (1) and at least one resistant filament yarn (2), the elastic filament yarn (1), at a maximum rate of elongation of the cable, is found to be wound in a helix around the resistant filament yarn (2) with a specific number of turns per linear meter of the cable (n.sub.sE) ranging between n.sub.sE-15% and n.sub.sE+15%, n.sub. sE being determined based on a specific formula, wherein the elastic filament yarn (1) moreover is also twisted about

66 | WIRE JOURNAL INTERNATIONAL

itself with a specific number of distinct turns about itself per linear meter of the cable ranging between n.sub.sE and 3.times.n.sub.sE, and the distinct turns about itself of the elastic filament yarn (1) is wound in the opposite direction from that of the said helix.

Method for packing cable U.S. Patent No.: 9,604,742 Patent date: March 28, 2017 Filed: April 28, 2014 Assignee: Furukawa Electric Co., Ltd. Nippon Telegraph and Telephone Corp., both Japan Inventors: Tetsuya Yasutomi, Masayoshi Tsukamoto, Noburu Okada, Shigeo Kimura, Shigeo Kihara, Keiichiro Sugimoto, Shinichi Niwa Provided is a method for packing a cable having a static friction coefficient of 0.15 or more and 0.50 or less, a dynamic friction coefficient of 0.10 or more and 0.40 or less and a bending rigidity of 60 gf or more and 350 gf or less. The method includes the steps of: (1) winding the cable into a figure-of-eight shape to form a cylindrical cable bundle, (2) winding a wrapping film as a restraining member, which restrains the cable bundle, around an outer circumferential portion of the cable bundle, (3) winding a wrapping film as a closing member which closes openings on both ends of the cable bundle, and (4) housing the cable bundle being wound with the restraining member and the closing member in a housing container.

Implantable medical leads having oscillating cable conductor lumens U.S. Patent No.: 9,604,049 Patent date: March 28, 2017 Filed: Nov. 16, 2015 Assignee: Cardiac Pacemakers, Inc., USA Inventors: Lily Lim, Devon Arnholt, Joel Eggert, Andrew De Kock, Paul Zarembo, Christopher Hartemink An electrical implantable lead includes an elongated lead body having a plurality of lumens therein, including at least one linear lumen and at least one planar, non-linear lumen and a plurality of conductor cables disposed within the plurality of lumens. The electrical implantable lead further includes a terminal connector coupled to a proximal end of the lead body, the terminal connector being in electrical communication with at least one of the plurality of

Triple helix driveline cable and methods of assembly and use U.S. Patent No.: 9,603,984 Patent date: March 28, 2017 Filed: Sept. 13, 2015 Assignee: Thoratec Corporation, USA Inventosr: Jaime Romero, Nathan Harold A power cable having improved durability and associated methods of assembly and use are described herein.

In one aspect, the power cable is adapted for use in powering an implantable circulatory pump system. The cable includes one or more conductors of uninsulated wire strands that are loosely packed so as to move relative one another during cable flexure. The driveline cable may include a plurality of conductors, each comprised of multiple uninsulated bundles of uninsulated, loosely packed wire strands of a conductive material, that are wrapped about a central core. The cable may include at least six conductors, each conductor having at least 200 wire strands of a 30 gauge or higher. The cable may include the plurality of wire strands wound in a Litz style configuration to provide improved durability over many cycles of use at reduced cost, improved integrity of the electrical connection and reduced diameter.

Multi-wire shielded cable and method for manufacturing such a cable U.S. Patent No.: 9,601,875 Patent date: March 28, 2017 Filed: Nov. 12, 2015 Assignee: MD ELEKTRONIK GmbH, Germany Inventor: Helmut Herrer A power cable having improved durability and associated methods of assembly and use are described herein.

In one aspect, the power cable is adapted for use in powering an implantable circulatory pump system. The

cable includes one or more conductors of uninsulated wire strands that are loosely packed so as to move relative one another during cable flexure. The driveline cable may include a plurality of conductors, each comprised of multiple uninsulated bundles of uninsulated, loosely packed wire strands of a conductive material, that are wrapped about a central core. The cable may include at least six conductors, each conductor having at least 200 wire strands of a 30 gauge or higher. The cable may include the plurality of wire strands wound in a Litz style configuration to provide improved durability over many cycles of use at reduced cost, improved integrity of the electrical connection and reduced diameter.

Hybrid cable with flat power conductors U.S. Patent No.: 9,601,235 Patent date: March 21, 2017 Filed: July 27, 2014 Assignee: CommScope Technologies LLC, USA Inventors: Frank Harwath, Scott Adams, Ronald Vaccaro A cable reduces loop inductance by changing the cross-sectional shape of the conductive elements of power supply and return conductors to something other than the traditional circular cross sectional shape, e.g., to a thin generally rectangular shape. The power supply and return conductors are also controlled in placement along the length of the cable, so that mutual inductance is maximized within a given power supply circuit, and minimized between the given power supply circuit and other power supply circuits within the cable. The return power supply conductor may optionally be sized for multiple power supply circuits, which may further reduce loop inductance and reduce crosstalk noise between different power supply circuits within a common cable. The power supply and return conductors may be part of a hybrid cable used to power and communicate with plural remote radio units proximate a top of a tower.

MAY 2017 | 67

PATENTS

conductor cables. Further, the electrical implantable lead includes at least one electrode coupled to the lead body.

TECHNICAL PAPERS ScienceDirect TECHNICAL PAPERS

Available online at www.sciencedirect.com

Procedia Engineering 166 (2016) 99 – 106

Available at www.sciencedirect.com 2nd International Symposium ononline Submerged Floating Tunnels and Underwater Tunnel Structures

ScienceDirect Recent Studies of Parametrically Excited Mooring Cables for Submerged Procedia Engineering 166Floating (2016) 99 – 106 Tunnels Daniel Canteroa*, Anders Rønnquista, Arvid Naessa a 2nd International Symposium on Submerged Underwater Norwegian University of Science andFloating Technology, Tunnels NTNU, 7491and Trondheim , Norway Tunnel Structures

Recent Studies of Parametrically Excited Mooring Cables for Submerged Tunnels Most current designs for Submerged Floating Tunnels (SFT)Floating include a mooring system to fix the position of these floating structures.

Abstract

Long period waves, such as swell waves, parametrically excite the system and might result in excessive vibrations in the cable.

This paper presents two distinct studies.

First, anaanalytical investigation of the asystem’s is aperformed to derive a closedDaniel Cantero *, Anders Rønnquist , Arvidstability Naess form expression, which allows for a quick evaluation of the system’s stability. This expression is obtained through the Harmonic a Norwegian University of Science and Technology, NTNU, 7491 Trondheim , Norway Balance Method (HBM) with two harmonic terms.

The contribution of multiple modes of vibration is investigated for the case of small sag to span ratios. The expression is compared with the results from a numerical model, revealing the applicability of the proposed formulation. The second study investigates the tension in the mooring line during parametric excitation. Correct design Abstract should avoid excessive forces that might break the line or very small forces that lead to momentarily slack cables. Thus, the aim of this study is to assess the validity of using the stability charts for the design of mooring lines with respect to safe levels of cable Most current for Submerged Floating Tunnels (SFT)ofinclude system to fix the position of these floating forces.

This designs is achieved through the numerical analysis a cablea mooring model using Abaqus.

Cable vibrations and cable structures. forces are Long periodforwaves, such as swell waves, parametrically the motions. system and might result in excessive vibrations in the cable. compared a range of amplitudes and frequencies of theexcite support This paper presents two distinct First, an analytical investigation of thethesystem’s stabilitylicense is performed to derive a closed© The Authors.

Published by studies.

Elsevier Ltd. Ltd. This is an open access article under CC BY-NC-ND © 2016 2016 The Authors.

Published

by Elsevier form expression, which allows for a quick evaluation of the system’s stability.

This expression is obtained through the Harmonic (http://creativecommons.org/licenses/by-nc-nd/4.0/).

Peer-review under responsibility of the organizing committee of SUFTUS-2016.

Balance Method with two harmonic terms.

The contribution of multiple modes of vibration is investigated for the case of Peer-review under(HBM) responsibility of the organizing committee of SUFTUS-2016 small sag to span ratios. expression is compared the results from a numerical Keywords: instability, cable,The mooring, parametric resonance,with submerged floating tunnel, tension model, revealing the applicability of the proposed formulation. The second study investigates the tension in the mooring line during parametric excitation. Correct design should avoid excessive forces that might break the line or very small forces that lead to momentarily slack cables. Thus, the aim of this study is to assess the validity of using the stability charts for the design of mooring lines with respect to safe levels of cable 1. Introduction forces. This is achieved through the numerical analysis of a cable model using Abaqus. Cable vibrations and cable forces are compared for a range of amplitudes and frequencies of the support motions.

The Norwegian government has decided to eliminate all ferries along the coastal highway E39 in order to reduce © Published

by Elsevier Ltd. Ltd. This is an open access article under the CC BY-NC-ND license © 2016 2016The TheAuthors.

Authors.

Published

by Elsevier travel time and boost local economy. This route crosses several fjords and there are currently eight ferry connections (http://creativecommons.org/licenses/by-nc-nd/4.0/).

Peer-review under responsibility of the organizing committee of SUFTUS-2016.

in operation toresponsibility cross them.ofThere are 5 fjord crossings where fixed links are to be built with widths over 2 km (up to Peer-review under the organizing committee of SUFTUS-2016 Keywords: instability, cable, mooring, parametric resonance, submerged floating tunnel, tension

1. Introduction

* Corresponding author. Tel.: +47-735-94521; fax:+47-735-94701.

E-mail address: daniel.cantero@ntnu.no

The Norwegian government has decided to eliminate all ferries along the coastal highway E39 in order to reduce travel time and boost local economy. This route crosses several fjords and there are currently eight ferry connections in operation to cross them. There are 5 fjord crossings where fixed links are to be built with widths over 2 km (up to

* Corresponding author. Tel.: +47-735-94521; fax:+47-735-94701.

E-mail address: daniel.cantero@ntnu.no

1877-7058 © 2016 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license

(http://creativecommons.org/licenses/by-nc-nd/4.0/).

Peer-review under responsibility of the organizing committee of SUFTUS-2016

doi:10.1016/j.proeng.2016.11.571

1877-7058 © 2016 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license

68 | 2ND INTERNATIONAL SYMPOSIUM / NORWAY (http://creativecommons.org/licenses/by-nc-nd/4.0/).

Peer-review under responsibility of the organizing committee of SUFTUS-2016

doi:10.1016/j.proeng.2016.11.571

Daniel Cantero et al. / Procedia Engineering 166 (2016) 99 – 106

5 km) and depths over 500 m (up to 5 km), where non-conventional engineering solutions will be necessary. One of the proposed solutions is the construction of a submerged floating tunnel (SFT), that, when built, will be the first of its kind worldwide. The preliminary studies have suggested a variety of possibilities with different cross sections and floating devices. However, any viable solution will need a mooring system to maintain the structure in the prescribed position (Fig. 1). The main environmental load in such a system will be the long period swell waves. This low frequency excitation produces a parametrically excited system. Certain situations might lead to parametric resonance or dynamic instability that causes excessive vibrations of the cable and the SFT. Nomenclature A ‫ܤ‬௜ c ‫ܥ‬௜ DAF DRF E L m N SFT

support motion amplitude auxiliary expression cable internal damping auxiliary expression Dynamic Amplification Factor Dynamic Reduction Factor material Young’s modulus Length of cable mass per unit length cable tension Submerged Floating Tunnel a

b

T TC ‫ݕ‬ሺ‫ݔ‬ǡ ‫ݐ‬ሻ ‫ݕ‬଴ ሺ‫ݔ‬ሻ ܻ௝ ሺ‫ݐ‬ሻ ߙ ȟܰሺ‫ݐ‬ሻ ߣଶ ߔ௝ ሺ‫ݔ‬ሻ ߱ ȳ

support motion period Transition Curve cable displacement static deformation of cable generalized coordinate cable inclination angle variation in cable tension Irvine’s parameter mode of vibration fundamental frequency of cable support motion frequency

Fig. 1. Submerged Floating Tunnel; (a) General view; (b) Cross-section; (Source: Snøhetta).

Parametric Excitation (PE) has been extensively studied in the field of differential equations and dynamic systems, [1] being one representative example. In bridge engineering this phenomenon has often been reported in cable stayed bridges [2] when girder or mast oscillations parametrically excite the cables. Similarly, in offshore platforms, parametric instability is an important aspect in the design of safe deep-water risers subjected to dynamic loads [3] and is still a hot research topic [4]. In the same way, in [5] the effect of PE on moored SFTs is analyzed. However, most of the published studies on parametric excitation in cables investigate exclusively the lateral displacements. Only a few of them examine also the cable tension. A very good example is [2] that provides qualitative explanations of various parametric resonances in a dry cable based on numerical simulation results. The relation between lateral displacements and cable tension under parametric resonance is not straightforward, particularly when considering nonlinear effects. To the best of the authors’ knowledge there is no study that explicitly investigates the tension of cables under parametric resonance including hydrodynamic effects. It is particularly interesting to evaluate the extreme cable stresses developed during parametric resonance. Very high cable tension might produce cable breakage. On the other hand, very small or no cable tension might result in momentarily slack cables, which might induce large impulse forces on the moored structure when it changes back to a taught line. Furthermore, the difference between the maximum and the minimum stresses defines the amplitude of the load cycle which is a fundamental parameter in correct assessment of the fatigue life.

MAY 2017 | 69

TECHNICAL PAPERS

100

TECHNICAL PAPERS

101

Daniel Cantero et al. / Procedia Engineering 166 (2016) 99 – 106

The aim of this paper is to introduce the studies currently being performed by the structural dynamics group at the Norwegian University of Science and Technology (NTNU). A summary of the most important findings published in [6, 7] is provided. Two distinct studies are reported in this document. The first study shows the derived analytical expression of the transition curves, which allows for a quick identification of the system’s stability. This expression is obtained through the Harmonic Balance Method (HBM) with two harmonic terms. The contribution of multiple modes of vibration is investigated for the case of small sag to span ratios. The expression is compared with the results from a numerical model, revealing the applicability of the proposed formulation. The second study focuses on the cable tension of the mooring system during parametric excitation. The validity of using the stability charts for the design of mooring lines with respect to safe levels of cable forces is assessed. This is achieved through the numerical analysis of a cable model. Cable vibrations and cable forces compared for a range of amplitudes and frequencies of the support motion.

2. Instability analysis This section derives the analytical expression of the Transition Curves (TC), which define the boundaries between stable and unstable solutions of a cable under parametric excitation. Then the expression is compared to the results obtained from a numerical model.

2.1. Equations of motion A mooring line of an SFT can be modelled as a cable suspended between two points. The wave loading excites the submerged structure inducing oscillations on one of the cable ends. This is represented as a cyclic imposed displacement of the upper boundary condition (Fig. 2a). The equation of motion can be derived considering a differential element of the cable, establishing the dynamic equilibrium and using D’Alembert’s principle: డమ ௬

డమ ௬

డ௬

݉ డ௧ మ ൅ ܿ డ௧ െ ൫ܰ ൅ ߂ܰሺ‫ݐ‬ሻ൯ డ௫మ െ ߂ܰሺ‫ݐ‬ሻ

డమ ௬బ డ௫ మ

(1)

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The equation can be solved by separation of variables, in which it is assumed that the solution is in the form of Eq. (2), where ܻ௝ ሺ‫ݐ‬ሻ are the generalized coordinates and the ߔ௝ ሺ‫ݔ‬ሻ the modes of vibration. ‫ݕ‬ሺ‫ݔ‬ǡ ‫ݐ‬ሻ ൌ σ௡௝ୀଵ ܻ௝ ሺ‫ݐ‬ሻ߶௝ ሺ‫ݔ‬ሻ;

߶௝ ሺ‫ݔ‬ሻ ൌ ‫ ݊݅ݏ‬ቀ

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ቁ

(2)

The variation of the tension in the cable is proportional to the cable length increment, which is equal to the combined contribution of three terms, as seen in Eq. (3). First, the cable length increment is equal to the displacement of the boundary condition along the cable chord. For displacements perpendicular to cable chord it can be approximated using a Taylor expansion and including the terms up to second degree. Similarly, the increment in length due to the cable dynamic deformation is approximated upon Taylor expansion and discarding higher order terms. ߂ܰሺ‫ݐ‬ሻ ൌ

ா஺ ௅

൬߂‫ݔ‬ሺ‫ݐ‬ሻ ൅

௱௬ሺ௧ሻమ ଶ௅

൅ σ௡௝ୀଵ

௝ మ గమ ௒ೕ ሺ௧ሻమ ସ௅మ

(3)

൰

Applying Galerkin’s method [2], the partial differential equation (Eq. (1)) is transformed into a system of second order differential equations. The general case is a set of coupled Mathieu equations. However, the coupling terms are small when the relation between sag and span is small [2]. This condition can be expressed in terms of Irvine’s parameter ߣଶ [8] that quantifies the relative importance of elastic and geometric effects. When ߣଶ ൏ ͲǤͳ, the system of equations can be uncoupled, obtaining a second order differential equation for each mode-j: ݉‫ܮ‬ଶ ܻఫሷ ൅ ܿ‫ܮ‬ଶ ܻఫሶ ൅

௝ ర గర ா஺ ସ௅మ

ܻ௝ ଷ ൅ ݆ ଶ ߨ ଶ ቀܰ ൅

ா஺ ௱௫ ௅

70 | 2ND INTERNATIONAL SYMPOSIUM / NORWAY

൅

ா஺ ௱௬ మ ଶ௅మ

ቁ ܻ௝ ൌ Ͳ

(4)

Daniel Cantero et al. / Procedia Engineering 166 (2016) 99 – 106

The support’s displacement in time is assumed to be harmonic with frequency ȳ and amplitude ‫ܣ‬, which can be written in terms of the cable’s inclination angle ߙ as follows: ߂‫ݔ‬ሺ‫ݐ‬ሻ ൌ ‫݊݅ݏ ܣ‬ሺߙሻ ܿ‫ݏ݋‬ሺߗ‫ݐ‬ሻ;

2.2. Analytical solution

߂‫ݕ‬ሺ‫ݐ‬ሻ ൌ ‫ݏ݋ܿ ܣ‬ሺߙሻ ܿ‫ݏ݋‬ሺߗ‫ݐ‬ሻ

(5)

Eq. (4) is the non-linear Mathieu equation where the excitation appears as time-varying coefficients [1] or parameters, thus called parametric excitation. A small parametric excitation can generate an unbounded solution (unstable solution). It is of great importance to identify when instability might occur. The boundaries that separate the stable from unstable solutions are termed Transition Curves (TC). One possibility to calculate the TC is through the Harmonic Balance Method (HBM) that essentially approximates the solution to Eq. (4) as a Fourier series (Eq. (6)).

Because the phase shift is unknown, both sin and cos must be included [2]. ܻ௝ ሺ‫ݐ‬ሻ ൌ σெ ௡ୀ଴ ߓሺଶ௡ିଵሻ ‫݊݅ݏ‬ሺ݊ߗ‫ݐ‬ሻ ൅ ߓଶ௡ ܿ‫ݏ݋‬ሺ݊ߗ‫ݐ‬ሻ

(6)

‫ ܣ‬ൌ േ‫ܤ‬ଵ ቆʹ‫ܮ‬ට‫ܤ‬ଶ ሺ‫ܤ‬ଷ േ ඥ‫ܤ‬ସ ሻቇ ݂‫ ܶ ݎ݋‬ൌ ʹߨ

(7)

Substituting Eq. (6) into Eq. (4), multiplying the result by the basis ሼ ሺȳ‫ݐ‬ሻǡ ሺȳ‫ݐ‬ሻǡ ǥ ǡ ሺ݊ȳ‫ݐ‬ሻǡ ሺ݊ȳ‫ݐ‬ሻሽ, integrating over one full cycle and balancing harmonic terms gives a system of equations with the Fourier coefficients ȯ௜ as the unknowns. Solutions of the system provide the Fourier coefficients that define periodic solutions for Eq. (4).

The transition curves are thus defined when the determinant of the coefficient matrix of the system is zero. The number of harmonic terms considered M defines the accuracy of the solution. In the literature only one term is generally considered. However, here two terms are considered (ܰ ൌ ʹ) because there is a significant increase in accuracy.

Analytical expressions for the TC are obtained with the aid of symbolic calculation software [9]. Two separate expressions are defined in Eq. (7) and Eq. (8), corresponding to periods 2ʌ and 4ʌ, which correspond respectively to the sum of all even and odd n values in Eq. (6) respectively. See the Appendix for complete definition of the auxiliary expressions ‫ܤ‬௜ and ‫ܥ‬௜ .

‫ ܣ‬ൌ േ‫ܥ‬ଵ ቆ‫ܮ‬ξʹට‫ܥ‬ଶ േ ඥ‫ܥ‬ଷ ቇ ݂‫ ܶ ݎ݋‬ൌ Ͷߨ

(8)

The expressions of the TC can be used to calculate the stability regions associated to any mode of vibration j.

Fig. 2b shows the stability chart derived from the analytical expressions for mode-j without damping. a

b

Fig. 2. (a) Sketch of mooring line model; (b) Analytical stability tongues for mode-j.

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2.3. Numerical validation The expressions derived in previous section allow us to identify situations that would produce large displacements in the mooring line due to harmonic movements of one of the boundary conditions. However, the analytical expression is only an approximation that needs to be compared against a numerical solution of the problem at hand. Therefore, a mooring line was modelled with ABAQUS [10] considering geometric nonlinearities. The cable is submerged in water and is thus influenced by drag forces and additional mass effects. These effects have been included by means of the Morison Equation using the toolbox AQUA provided by the software. Two important parameters are necessary, namely the added mass coefficient CA and the drag coefficient CD whose numerical values are 1 and 1.5 respectively as recommended in [11]. The particular cable properties used in this study are provided in Table 1.

Table 1. Numerical values of cable properties.

Symbol

Description

Value

L

Length

100

Unit m

E

Young’s modulus

210·109

N/m2

A

Area

785.40

cm2

į

Density

7800

kg/m3

İ

Damping

0.1

%

N

Initial tension

2·106

N

݂ଵ

Fundamental frequency

0.8493

Hz

The analytical expression derived in Section 2.2 is compared against the numerical solution in Fig. 3. In order to find the analytical stability map for our model it is necessary to consider the contribution of several modes. This can be achieved by superimposing as many modes as deemed necessary. Fig. 3 shows the stability chart for the particular cable defined in Table 1 considering 7 modes and 5% damping. The formulation allows us to easily include the contribution of higher modes of vibration. In particular it is important to include the first and second instability regions of each mode. The numerical stability map is obtained analyzing the results from 1320 separate simulations for a range of excitation frequencies and amplitudes. In particular, the ratio ȳȀ߱ is varied in a discrete space with values from 0.25 to 3.5 in increments of 0.05, whereas the considered amplitudes are from 0.005m to 0.1m in 0.005m increments.

It can be seen that there is a good match between the stability predictions derived from the closed-form expressions and the numerical solution.

Fig. 3. Stability chart for 7 modes of vibration (shaded areas). Numerical solutions: small black dot = stable; big red dot = unstable.

3. Mooring line tension This section analyzes the tension of the mooring line during parametric excitation. First, one particular example is shown to illustrate the different effect of parametric resonance on different load effects, namely lateral displacements

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and total cable tension. Then the extreme values of tension are investigated for the same range of motion amplitudes and frequencies as in Section 2.3.

3.1. Tension during parametric resonance One particular situation is shown in Fig. 4 that corresponds to the mooring line with a support motion with a frequency ratio (ȳȀ߱) of 2 and an amplitude A of 0.1 m. Fig. 4a shows the lateral displacements at the mid-span of the cable. For graphical reference, the maximum and minimum static vertical displacements are shown ௌ௧௔௧௜௖ ௌ௧௔௧௜௖ ܽ݊݀ ‫ݑ‬௠௜௡ ), which correspond to A and -A. Note that the time-history corresponds to lateral displacements, (‫ݑ‬௠௔௫ whereas the references are for vertical displacements. Even though the results are for different directions it is still useful to compare how much bigger the displacements are compared to the support motions in a parametric resonant situation. The time-history shows the typical response for such a system under parametric resonance. The displacements grow exponentially over time until a certain maximum (or minimum) value is reached. For this particular case the maximum displacement is 0.5068 m while the amplitude of the support motion is only 0.1 m, this is more than 5 times greater. a

b

Fig. 4. Results for harmonic support motion (ȳȀ߱= 2; A = 0.1 m) a) Lateral displacement at mid-span; b) Tension at support.

Intuition would suggest that the internal cable tension should have a similar evolution in time, or at least feature some significant growth at the same time as those reported for the displacements. But this is not the case. Fig. 4b shows the time-history of the total tension at the upper support. For reference, the initial cable tension N is shown, also the static tension for situations with the maximum and minimum support displacements are indicated respectively ௌ௧௔௧௜௖ ௌ௧௔௧௜௖ and ܰ௠௜௡ . It can be seen that the tension values are barely affected by the parametric resonance. There is as ܰ௠௔௫ ௌ௧௔௧௜௖ only a slight increase of the maximum tension. At the same time, the minimum tension values are greater than ܰ௠௜௡ during steady-state. This means that during parametric resonance the possibility of reaching a slack cable situation actually reduce.

It has to be noted that higher (and lower) values of tension are obtained at the very beginning of each of the simulations. This is due to the sudden start of the support motion, which produces a small temporary increase of the ௌ௧௔௥௧ ௌ௧௔௥௧ and ܰ௠௜௡ in Fig. 4b. These extreme tension values are not really interesting for our tension and indicated as ܰ௠௔௫ analysis and are only a consequence of the way of modelling the problem. In reality, the amplitude of the support

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motion will grow gradually. For this reason, the first 10 cycles of each simulation are neglected when calculating the maximum (and minimum) tension values.

3.2. Parametric study To analyze the changes in tension it is convenient to define them in terms of dynamic factors. Here two distinct factors are used to clearly differentiate the results between maximum tension and minimum tension. The factor is a normalization of the extreme values of the tension with respect to the calculated extreme static response corresponding to the extreme support motions. We define Dynamic Amplification Factor (DAF) and Dynamic Reduction Factor (DRF) in Eq. (9). For the maximum tension DAF is greater than or equal to one. Conversely, the factor for the minimum (DRF) is smaller than or equal to one. These factors allow us to study the problem from the static design perspective. The mooring line can be studied statically based on the expected support motion amplitude and then factored to obtain the maximum and minimum tension values. ‫ ܨܣܦ‬ൌ

ே೘ೌೣ

ೄ೟ೌ೟೔೎ ே೘ೌೣ

൒ ͳ;

‫ ܨܴܦ‬ൌ

ே೘೔೙

ೄ೟ೌ೟೔೎ ே೘೔೙

(9)

൑ͳ

It is interesting to explore how the instability diagram for lateral displacements (Fig. 3) relates to the maximum and minimum cable tensions. Fig. 5a shows the maximum cable tension in terms of DAF. Some of the instability tongues reported in Fig. 3 can also be seen here. However, the maximum DAF for any ȳȀ߱ and A combination is 1.0165, which means that the maximum total tension (static + dynamic) is only 1.65% greater than the maximum static. But it is even more interesting to study the DRF as presented in Fig. 5b. The minimum tension in the cable is either equal to the minimum static or just slightly smaller. This is reflected in the DRF values that have an absolute minimum value of 0.9937. This is, the minimum tension is 99.37% of the minimum static, or in other words, there is only a 0.67% reduction of the total tension when compared to the static one. The instability tongues in Fig. 3 can also be seen in Fig. 5b but, in this case, the values of DRF during parametric resonance are equal to one. As seen before in Fig. 4b, during parametric resonance the minimum tension grows above the minimum static value, hence achieving a value of 1 for the DRF. a

b

Fig. 5. Normalized extreme tension for submerged cable; (a) Maximum (DAF); (b) Minimum (DRF).

4. Conclusion This paper revisits the problem of parametric excitation of mooring lines. First, by means of the Harmonic Balance Method, an analytical expression of the unstable configurations has been obtained. The formulation allows for the contribution of multiple modes of vibration in situations with small sag to span ratios. The formulation is then validated against the results from a numerical model. The analytical expression can easily be integrated in the design process to avoid situations that might lead to parametric excitation.

The second study investigated the cable for a wide range of excitation amplitudes and frequencies. The maximum and minimum cable tensions are studied in terms of DAF and DRF, which are normalized dynamic factors that allow us to quickly assess the extreme tension values with respect to the static case. Even though the tension values show some correspondence with the instability diagrams, their numerical values are remarkably small. The results clearly

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show small increase/reduction in the maximum/minimum cable tension compared to the static case. Therefore, there is no risk for cable breakage or slack cable if the static design of the mooring line is done with sufficient safety margins.

Acknowledgements The research presented in this manuscript was possible thanks to the financial support of The Fjord Crossing research program for the Coastal Highway Route E39.

Appendix A. Auxiliary expressions in Eq. (7): ‫ܤ‬ଵ ൌ

ଵ

(A.1)

గయ ா஺஻మ ଶ ଶ

ଶ

‫ܤ‬ଶ ൌ ͺ‫ ݉ ߗ ܮ‬െ ͵ܰߨ ‫ܤ‬ଷ ൌ ͳ͸‫ ߨ ଺ߗ ଺ܮ‬ଶ ݉ଷ ൅ Ͷ‫ߗ ଺ܮ‬ସ ߨ ଶ ܿ ଶ ݉ െ ʹͺ‫ܮ‬ସ ܰߗସ ߨ ସ ݉ଶ െʹ‫ܮ‬ସ ܰߗଶ ߨ ସ ܿ ଶ ൅ ͳͶ‫ܮ‬ଶ ܰ ଶ ߗଶ ߨ ଺ ݉ െ ʹܰ ଷ ߨ ଼ ‫ܤ‬ସ ൌ ʹͷ͸‫ܮ‬ଵଶ ߗଵଶ ߨ ସ ݉଺ ൅ ͳʹͺ‫ܮ‬ଵଶ ߗଵ଴ ߨ ସ ܿ ଶ ݉ସ െ ͹͸ͺ‫ܮ‬ଵ଴ ܰߗଵ଴ ߨ ଺ ݉ହ ൅ͳ͸‫ܮ‬ଵଶ ߗ଼ ߨ ସ ܿ ସ ݉ଶ െ ͳʹͺ‫ܮ‬ଵ଴ ܰߗ଼ ߨ ଺ ܿ ଶ ݉ଷ ൅ ͺ͸Ͷ‫ ܰ ଼ܮ‬ଶ ߗ଼ ߨ ଼ ݉ସ ൅ͳ͸‫ܮ‬ଵ଴ ܰߗ଺ ߨ ଺ ܿ ସ ݉ ൅ ͵͸‫ ܰ ଼ܮ‬ଶ ߗ଺ ߨ ଼ ܿ ଶ ݉ଶ െ Ͷ͸Ͷ‫ ܰ ଺ܮ‬ଷ ߗ଺ ߨ ଵ଴ ݉ଷ െͺ‫ ܰ ଼ܮ‬ଶ ߗସ ߨ ଼ ܿ ସ ൅ ͳ͸‫ ܰ ଺ܮ‬ଷ ߗସ ߨ ଵ଴ ܿ ଶ ݉ ൅ ͳʹͻ‫ܮ‬ସ ܰ ସ ߗସ ߨ ଵଶ ݉ଶ െ͹‫ܮ‬ସ ܰ ସ ߗଶ ߨଵଶ ܿ ଶ െ ͳͺ‫ ܰ ଼ܮ‬ହ ߗଶ ߨ ଵସ ݉ ൅ ܰ ଺ ߨ ଵ଺ Auxiliary expressions in Eq. (8): ‫ܥ‬ଵ ൌ

ଵ

ସா஺గర ସ ସ ସ

ଶ

ସ

ଶ ସ ଶ

ଶ

ଶ ଺

ଶ ଼

‫ܥ‬ଶ ൌ ͻͻ‫ ݉ ߨ ߗ ܮ‬൅ ͳʹ‫ ܿ ߨ ߗ ܮ‬െ ͳͷʹ‫ ݉ ߨ ߗܰ ܮ‬൅ Ͷͺܰ ߨ ‫ܥ‬ଷ ൌ ͻͶ͹͹‫݉ ଼ ߨ ଼ߗ ଼ܮ‬ସ ൅ ͻ͵͸‫ ܿ ଼ ߨ ଺ߗ ଼ܮ‬ଶ ݉ଶ െ ʹ͹ʹͳ͸‫ ܰ ଺ܮ‬ଵ ߗ଺ ߨ ଵ଴ ݉ଷ െͶ͵ʹ‫ߗ ଼ܮ‬ସ ߨ ଼ ܿ ସ െ ͳ͵ͶͶ‫ߗܰ ଺ܮ‬ସ ߨ ଵ଴ ܿ ଶ ݉ ൅ ʹͷͲͷ͸‫ܮ‬ସ ܰ ଶ ߗସ ߨ ଵଶ ݉ଶ െͳͶͲͺ‫ܮ‬ସ ܰ ଶ ߗଶ ߨ ଵଶ ܿ ଶ െ ͻͶ͹ʹ‫ܮ‬ଶ ܰ ଷ ߗଶ ߨ ଵସ ݉ଶ ൅ ͳʹͺͲܰ ସ ߨ ଵ଺

(A.2) (A.3)

(A.4) (A.5) (A.6) (A.7)

References

[1] A.H. Nayfeh, D.T. Mook,Nonlinear Oscillations, Wiley-VCH, Germany, 2004.

[2] J.L. Lilien, A. Pinto Da Costa, Vibration amplitudes caused by parametric excitation of cable stayed structures, J. Sound Vib. 174 (1994) 69-90.

[3] F. Xiao, H.Z. Yang, Probabilistic assessment of parametric instability of a top tensioned riser in irregular waves, J. Marine Sci. Tech. 19 (2014) 245-256.

[4] H. Yang, F. Xiao, P. Xu, Parametric instability prediction in a top tensioned riser in irregular waves. Ocean Eng. 70 (2013) 39-50.

[5] S.N. Sun, Z.B. Su, Parametric vibration of submerged floating tunnel tether under random excitation. China Ocean Eng. 25 (2011) 349356.

[6] D. Cantero, A. Rønnquist, A. Naess, Parametric excitation of mooring cables for submerged floating tunnels, IABSE conference, May 2016, Guangzhou, China.

[7] D. Cantero, A. Rønnquist, A. Naess, Study of tension in mooring cables under parametric excitation for submerged floating tunnels, 19th IABSE Congress, September 2016, Stockholm, Sweden.

[8] M. Irvine. Cable Structures, The MIT Press, Cambridge, USA, 1981.

[9] MAPLE 18, Maplesoft, a division of Waterloo Maple Inc. Waterloo, Ontario.

[10] ABAQUS, Analysis user’s manual, Dassult Systemes, Providence, 2011.

[11] Det Norske Veritas SA, Recommended Practice DNV-RP-C205: Environmental Conditions and Environmental Loads, 2014.

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TECHNICAL PAPERS De evelopment of Siingle-Cry ystal Wire e and Ca able M Min Su Ka ang*, Hong g Seok Cho oi*, Hoon C Chul Yang g*†, San ng Eon Parrk** and Se e Young Je eong** * Cable Technology Research an nd Incubation n Group, LS C Cable and Syystems Ltd., Gunpo-si, Gyeongi-do, R Republic of Ko orea epartment of Cogno-Mech hatronics Eng gineering, Pu usan Nationa al Univ., Mirya ang-si, Gyeo ongnam, ** De R Republic of Ko orea +82-31-4 450-8235 · email addresss: goodman@ @lscns.com Ar gas of 5 N purrity. The crucible and copper w were heated throuugh thee RF induction method with ann RF generator (40 kHz, 20 kW W).

Thhe pulling speed was 3 mm/h, an and the rotation speed was 10 rppm.

Thhe grain-free SCC C wires were faabricated from a bulk single crystal by a wire electriical discharge machine (wire--EDM, Mitsubiishi A10S, Japan). T This uses the raapid series of rrepetitive electriical FA disscharges to remoove small amounnts of material, w with very thin w wire serrving as the electrode.

A Abstract Single-crystal copper (SCC) has a low elecctrical resistivitty and aan excellent grrain free structuure compared with that of geeneral eelectric copper or oxygen-free copper. In this study, we deveeloped a new wire annd cable fabriication processs that preserveed the m minimized grainn boundaries (G GBs) structure oof the SCC grow wn by tthe Czochralskii method. The ddeveloped wiree and cable show wed a cconductivity ennhancement com mpared to the innternational annnealed ccopper standardd (IACS) resistivity and betteer characteristiccs for aapplication of audio/video caables. The deveeloped single-ccrystal ccopper wire andd cable could bee used for largee-scale productioon for nnew specialty ccable area.

F Figure 2 (a) andd (b), respectiveely shows a scheematic of the wireED DM process for fabrication of thhe SCC disk andd wire. In standdard cuttting methods, including diam mond saw andd mechanical w wire cuttting, the crystall structure of thee cut surface is affected due to the exccellent ductility and malleabilityy of copper. As shown in Figuree 2, thee wire-EDM ussed a rapid seriies of electricall discharges to cut cerrtain areas of tthe metal, withh very thin wiire serving as the eleectrode. The cuttting wire, which did not directtly touch the meetal

Keywords: w wire; cable; singgle crystal; resisttivity, grain bouundary

1. Introdu uction

Table 1. Resistivity o of copper and d silver

The SCC m material can bee fabricated byy using Czochhralski pprocess. Since there is no grrain boundary (GB) in the singleccrystal copper, the quality of electronic siggnal transmissiion is eexcellent. Espeecially, becausee single crystall has no defecct, the nnoise during eleectronic signal transmission alllowing the cablle can bbe reduced. Thherefore, in caase of using siingle crystal foor the cconductor, the single s crystal wire w showed bettter characteristiics for aapplication of audio and videeo cables as weell as a conducctivity eenhancement compared c to tthe internationnal copper staandard ((IACS) resistiviity.[1]

M Metal

Resistivity ρ(Ω·m)

Coopper

1.69 X 10-8

Copper siingle crystal

1.54 X 10-8

HIP treated Cu C single crystaal

1.47 X 10-8

Silver

1.62 X 10-8

Silver sinngle crystal

1.49 X 10-8

Table 1 shoows the generaal resistivity off copper and silver. s R Resistivity of ssingle crystal coopper decreasedd with 9% com mpared tto that of coppper. Further com mpare to silver,, resistivity of ssingle ccrystal copper decreased 5%. However, it cannot be corrrectly aapplied to the cable c because vvarious processses should be nneeded ffor the manufaccture of the cabble. In this woork, the SCC wiire by uusing Czochralsski method wass fabricated andd the resistivity of the ccables by usingg the SCC was iinvestigated. Thhe microstructurre and rresistivity of ccable was anallyzed and com mpared to the other cconventional coopper, OFC andd SCC for the coonductor.

2 2. Experim mental 2 2.1 Manufacturing of siingle crystall copper c conductor c cable Figure 1 show ws (a) the scheematic diagram of the crystal ggrowth ssystem and (b) the SCC (singgle crystal coppper) whisker. C Copper bbeads with 4 N purity (Sigm ma-Aldrich) weere used as sttarting m material for crysstal growth. Thee SCC was grow wn by the Czochhralski m method in a graaphite crucible. In I order to avoidd the oxidation of the ggraphite cruciblle and copper, tthe vacuum chaamber was filledd with

76International | 65TH IWCS CONFERENCE PAPER Wire & Cable Symposium

Fig gure 1. (a) Sc chematic of th he crystal gro owth system, (b) Photo--graph of the grown coppe er single crys stal

658

Proceedings of the 65th IWCS Conference

TECHNICAL PAPERS (aa)

Figure 2. (a) Fabrication o of SCC disks by wire-EDM, (b) abrication pro ocess for SCC C wire in a spirral Fa fashion through h wire-EDM cutting, SCC disk and SCC wire, (c)) Fabricated S (d) Straighttened SCC wire. (bb)

ssample, was sllowly fed throuugh the materiaal, and the elecctrical ddischarges cut the t material. We W found that thhe wire-EDM method m w was suitable forr fabricating mettallic single-crysstal wire. Figuree 2 (c) aand (d) shows thhe fabricated SC CC disk and wirre. The SCC wirre was ffabricated from m the SCC diskk through wire-E EDM cutting. IIt was ppossible to preppare SCC diskss of arbitrary thhickness. From m SCC ddisks of 1 mm tthickness, the fa fabricated SCC wires w were fabrricated iin a spiral fashiion. The single--crystal wires, 11mm wide and 1 mm tthick, were obtaained by straighhtening the spirrally processed disks.

T Then, it was appplied to cold wire drawing pprocess by usinng the ffabricated and connected SCC C wire with iniitial square-shappe. In oorder to make a cable for speccial applications such as audio, video ccable and so onn, it was progreess stranding process and extrruding pprocess for insuulation and sheatth step by step.

F Figure 3. (a) s showed whole e process of m manufacturing g cable and (b) the fabricated au udio cables by y u using the SCC C conductors.

3. Results a and discu ussion 3.1 1 Microstru ucture F Figure 4 showss SEM image of a various tyype of copper for lonngitudinal direcction by usingg FIB SEM. F Figure. 4 are (a) connventional OFC C and (b) PCOCC (Pure Copperr Ohno Continuoous Caast, Furukawa) annd (c) cold draw wing SCC and (dd) rectangular SCC wirre after EDM ccutting. OFC annd PCOCC shoowed thin and loong cryystal as drawn direction. On tthe other hand, cold drawn SCC shoowed thicker annd larger crystaal compared to OFC and PCOCC cryystal. Further S SCC wire after EDM cutting showed no grrain bouundary because the crystal was formed into singgle.

2 2.2 Test me ethod The resistivity was measured in i the room temp mperature using a 4-He ccryostat (PPMS S Quantum Dessign, USA). Eleectrical contactss were m made using puure gold wires 0.0508 mm in diameter and silver eepoxy on the ssample. For ressistivity measureements, we useed the ffour probe meth thod and the cuurrent-reversal m method (delta m mode).

G Generally, the ffour-probe methhod can eliminaate low-level vooltage eerrors by removving the contacct resistance usiing two extra pprobes bbetween the currrent contacts. To T minimize thee unwanted addiitional vvoltages due to the thermoelecctric effect, we m measured the vooltage w with the currrent in one ddirection, and then repeatedd the m measurement with w the reversedd current (delta mode). This cuurrentrreversal methodd gave reliable rresults by remooving the tempeerature ddifference bettween the tw wo readings. In the resisstivity m measurements, we used a naanovoltmeter (K Kiethley 2182A A) for m measurement oof the voltage difference annd a current ssource ((Kiethley 2425)). And in orderr to obtain microstructure of ccopper w wires, we perfoormed SEM imaage by using FIB B-SEM (Focuseed Ion B Beam Scanningg Electron Microoscope) analysis.

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Fiigure 5 shows SEM image of o a various tyype of copper for trannsverse direction by using FIB SEM. With sim milar to longitudiinal dirrection, a lot of small crystal can be shownn in the OFC aand PC COCC. Howeveer, the SCC wirre also showed no grain bounddary of crystal. It is thhought that the single crystal m microstructure w was wing slippped and crackked with each other during the cold draw proocess. Howeveer, the crystal m microstructure hhas still large grrain size and continuoous crystal with the longitudinaal direction. Thhus, bettter electric connductivity for thee conductor woould be obtainedd as com mparing with that of OFC and P PCOCC.[2]

3.2 2 Conductiv vity Fiigure 6 and Tabble 2, showed thhe resistivity of the various coppper typpes by using PPMS. P The ressistivity of OFC C is measured as 1.6684x10-8 Ω·cm. The resistivity of PCOCC is same value thaat is ablle to change to the IACS valuee of 100%. Thiis is slightly woorse vallue compared too theoretical valuue, because the copper was woorkharrdened that increases the internnal stress to the material m during the colld drawn processs. On the other hands, the resisstivity of SCC w wire -8 is measured m as 1.55945x10 Ω·cm m and can be chaanged to the IA ACS

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Figure 4. F FIB-SEM image for longitud dinal direction n of (a) OF FC and (b) PCO OCC and (c) c cold drawn SCC and (d) SCC w wire after EDM M Cutting

Figure 6. Con nductivity by using PPMS o of (a) OFC and d (b) PC COCC and (c) cold drawn S SCC and (d) SCC EDM Cutting wire after E stic of copper materials w with Table 2. Electrric characteris varietty type

mage for cros ss-sectional Figure 5. FIB-SEM im C and (c) cold d direction of (a) OFC and (b) PCOCC CC wire afterr EDM Cutting g drawn SCC and (d) SC tthat has 105.6% % value. After SCC wire was done to cold drawn d pprocess, the resistivity was sllightly increased up to 1.652 x10-8 Ω Ω·cm and channged to the IAC CS of 101.9 % value. These rresults sshowed that thee conductivity oof cold drawn SC CC is good aboout 1.9% aas compare to that of OFC and PCOCC w wires. Moreoveer, the cconductivity off the SCC wire without cold drawing d process was iincreased up to 5.6%.

4 4. Conclu usions

78 | 65TH IWCS CONFERENCE PAPER

5. Acknowlledgments s Sppecial thanks to the Civil M Military Coopeeration Center for suppporting the cabble research and this year’s publiication.

6. Referenc ces

In this workk, the single crrystal copper (S SCC) wire by using C Czochralski meethod was fabrricated, and the special cablee was m manufactured bby using the S SCC wire with cold drawing,, after bbunching and innsulation processses. SEM imagges of the cold drawn d S SCC showed larger crystal than that of conventional ccopper m materials. And it is effective tto conductivity as a conductorr. The rresistivity of SC CC wire is 1.59945x10-8 Ω·cm m and shows thee high vvalue of 105.6% % with the indexx of IACS. Afterr cold drawn prrocess,

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thee resistivity waas slightly downn to 1.652 x100-8 Ω·cm and has 101.9%. As a reesult of evaluatiion of microstruucture and elecctric prooperties, the maanufactured cablle can have goood performance for redducing the resisstivity and imprroving better trransmission of the siggnal with higgh electric coonductivity resulted from the chaaracteristic of siingle crystallinee microstructuree as compared w with thaat of the conventtional copper. It is thought that tthe developed w wire andd cable using thee SCC will be uusefully applied tto the AV cable.

[1]] Y.C. Cho, S.H H. Lee, Muhamm mad Ajmal, W.K K. Kim, C.R. Chho, S.Y. Jeong, JJ.H. Park, S.E. Park, S.k. Park k, H.K. Park annd

Copper Better than t Silver: Eleectrical H.C. Kim “C Resistivity oof the Grain-Frree Single-Cryystal Copper W Wire” Crystal Grow wth&Design Article A 2010, Vool. 10, 27802784 K.Y. Kim, “Creeep Densificatio on Behavior off [2]] H.C. Yang, K

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Micro and Nano Metal Powder: Grain-size-dependent Modelâ&#x20AC;? Acta Materialia 2006, Vol. 54, 3779-3790

Authors

Min Su Gang, joined LS Cable and Systems Ltd. in 2013 after receiving his M.S. degree as a Material Engineer from Pusan University. He has been involved in the LV/MV and specialty cable design and development. He is currently working in Cable Technology Research and Incubation Group.

Sang Eon Park, joined Research Center for Dielectric and Advanced Matter Physic in 2004 after receiving his Ph.D. in Physics in Pusan National University. He has been involved in the metal single crystal growth, production, process and development of single crystal cable and wire. He is currently working in Crystal Bank in Pusan National University and Max-Crystal Laboratory, Co., Ltd.

Hong Seok Choi, joined LS Cable and Systems Ltd. in 2015 after receiving his Ph.D. degree as a Mechanical Engineer from Pusan University. He has been involved in the Industrial and specialty cable design and development. He is currently working in Cable Technology Research and Incubation Group.

Se Young Jeong, received his Ph. D (Dr. rer. nat.) in Koeln University (Germany), as Crystal Physics and Crystallography in 1990. He joined to Electronics and Telecommunications Research Institute (ETRI) in 1990, and moved to Pusan National University in 1991. He served as general affair secretary in the Korean Physical Society (2009-2011), editor-in -chief of Current Applied Physics in 2013-2014, and dean of the college of Nanoscience and Nanotechnology, Pusan national university. His major research areas are the single crystal research and development, metal single crystal thin film, and spintronics. He is currently working as a director of Crystal Bank institute in Pusan National University, and as CEO of Max-Crystal Laboratory, Co. Ltd.

Hoon Chul Yang, received his Ph.D. degree as a Mechanical Engineer and Advanced Mechanical Designer form Pohang University of Science and Technology (POSTECH) in 2005. He joined LS Cable and Systems Ltd. in 2004 as a Cable Technology Research Engineer in R&D Dept. and since then he has been involved in development, production, process engineering and outside plant engineer of LV/MV, Industrial, Optical and Specialty Cable. He is currently responsible for developing high performance cables, and managing with Cable Technology Research and Incubation Group in LS Cable and Systems Ltd. Hoon Chul Yang is a member of IEC TC20 Committee in Korea.

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Procedia CIRP 40 (2016) 18 – 23

13th Global Conference on Sustainable Manufacturing - Decoupling Growth from Resource Use

ChallengesAvailable and Approaches for a Continuous Cable Production online at www.sciencedirect.com Mustafa Severengiz*, Tobias Sprenger, Günther Seliger ScienceDirect Technische Universität Berlin, Department of Assembly Technology and Factory Management, Pascalstr. 8-9, 10587 Berlin, Germany * Corresponding author. Tel.: +49 (0)30/314-25549; fax: +49 (0)30/314-22759.

Procedia CIRP 40 (2016) 18E-mail – 23 address: Severengiz@mf.tu-berlin.de

13th Abstract

Global Conference on Sustainable Manufacturing - Decoupling Growth from Resource Use

The shut-down of nuclear power plants and the general shift from fossil to regenerative energies lead to an increase of disparity between energy production and energy consumption in Germany. Because of the immense acceptance problems among the public against overhead lines and underground cables new solutions are needed. After considering various options the idea of a tunnel along the highway for the electricity transmission was selected within a VDE Severengiz*, study as a promising option. Since joints are Günther expensive and a source of failure and the transportation of Mustafa Tobias Sprenger, Seliger cables that are longer than one kilometer is barely possible on land, on-site production is considered as an alternative. To make a production onTechnischemore Universität Berlin,challenges Departmentand of Assembly Technology and Factory Management, Pascalstr.

8-9, 10587 Berlin, Germany site economically attractive, first approaches towards a continuous HVDC cable production are described.

Authors. Published by Elsevier Elsevier B.V. B.V. This is an open access article under the CC BY-NC-ND license © 2016 The * Corresponding author. Tel.: +49 (0)30/314-25549; fax: +49 (0)30/314-22759. E-mail address: Severengiz@mf.tu-berlin.de Peer-review under responsibility of the International Scientific Committee of the 13th Global Conference on Sustainable Manufacturing. (http://creativecommons.org/licenses/by-nc-nd/4.0/).

Peer-review under responsibility of the International Scientific Committee of the 13th Global Conference on Sustainable Manufacturing

Challenges and Approaches for a Continuous Cable Production

Keywords: cable production; extrusion; degassing chamber; HVDC

Abstract

Introduction [3]. Therefore, considering thebetween publicenergy concerns The1. shut-down of nuclear power plants and the general shift from fossil to regenerative energiesnew lead solutions to an increase of disparity must be developed. production and energy consumption in Germany. Because of the immense acceptance problems among the public against overhead lines and The rise of renewable energy usage asAfter wellconsidering as the impact of options A the study the along Association for Electrical, Electronic underground cables new solutions are needed. various ideadone of a by tunnel the highway for the electricity the events Fukushima, development andare Information Technologies (VD –and in German: Verband transmission wasinselected withinJapan, a VDE makes study asaafurther promising option. Since joints expensive and a source of failure the transportation of der cables longer than one kilometer is barely possible on land, on-site is considered as an alternative. make a production on- has of that the are electricity transmission grid in Germany inevitable in production Elektrotechnik, Elektronik und To Informationstechnik) site recent economically attractive, challenges and firstpower approaches towards a continuous HVDC cable production are described. years.more The increase of wind generation shown, that a grouping of power cables in a tunnel-based Elsevier B.V. Thiswith is an open under thenext CC BY-NC-ND license © 2016 The Authors.

Published

by Elsevier B.V. transforms northern regions of Germany low access energyarticlesolution to the existing highways might be a promising 13th Global Conference Sustainable Peer-review under responsibility Internationalcenters Scientificwhile Committee (http://creativecommons.org/licenses/by-nc-nd/4.0/). consumption into powerof the generation the of the compromise between onthe need Manufacturing. for new electricity Peer-review under responsibility of the International Scientifi c Committee of the 13th Global Conference on Sustainable predominant industry region in the south is shutting down transmission, and the public Manufacturing protests against visible Keywords: cable production; extrusion; degassing chamber; HVDC

their nuclear power plants. This imbalance creates a high transmission routes and the influence of underground cables demand for electricity transmission, for which the existing on the environment [4]. Another enormous advantage is, that alternating current (AC) grid is insufficient because of its huge [3].ifTherefore, the tunnel new has once been considering built, the capacity of the electricity 1. Introduction solutions the public concerns electricity losses for longer distances [1]. Therefore, direct must transmission can be raised without interminable permission be developed. electricity transmission dueasto increase current processes.

Furthermore, a tunnel for nextElectrical, to the highway might The rise (DC) of renewable energy usage as is well theanimpact of of A study done by the Association Electronic distancesJapan, not only needed for sea, but also for andsimplify a realization due (VD to a –good infrastructural the transmission events in Fukushima, makes a further development Information Technologies in German: Verbandlocation der landelectricity connections. and possibly Elektronik less non-governmental property crossed of the transmission grid in Germany inevitable in Elektrotechnik, und Informationstechnik) has in cheapest solution of is towind build power a new net of overhead shown, to a tunnel an underground across the comparison recent The years.

TheDC increase generation that a grouping of or power cables in a cable tunnel-based be theenergy usage of solution lines. Another, more expensive solution would country side. transforms northern regions of Germany with low next to the existing highways might be a promising undergroundinto cables.

However due to massive acceptance Therefore, a consortium members consumption power generation centers while the compromise between the of need for from new universities electricityand problems industry within the public, bothsouth solutions are difficult new approach connect generation industry is working predominant region in the is shutting down to transmission, and theon apublic protests to against visible in Germany [2]. The importance the changeover and load centers in Germany by high voltage direct current theirrealize nuclear power plants.

This imbalanceof creates a high to transmission routes and the influence of underground cables more for renewable energies in the for gridswhich is accepted by the on the (HVDC) transmission within enormous a tunnel. The projectis,isthat called demand electricity transmission, the existing environment [4]. Another advantage general current public, (AC) but there still the “not in my backyard” OVANET – once Overlay Option of forthetheelectricity Future. An alternating grid isisinsufficient because of its huge if the tunnel has beenGrids built,astheancapacity understood a meshed highway for the (NIMBY) discussion for distances each electricity transmission route transmission overlay grid electricity losses for longer [1]. Therefore, direct cancan be be raised withoutasinterminable permission electricity transmission, whichnext is laid in highway addition might onto the current (DC) electricity transmission is due to an increase of processes.

Furthermore, a tunnel to the transmission distances not only needed for sea, but also for simplify a realization due to a good infrastructural location land connections. and possibly less non-governmental property crossed in The cheapest DC solution is to build a new net of overhead comparison to a tunnel or an underground cable across the lines. Another, more expensive solution would be the usage of country side. underground cables. However due to massive acceptance Therefore, a consortium of members from universities and problems within the public, both solutions are difficult to industry is working on a new approach to connect generation realize in Germany [2]. The importance of the changeover to and load centers in Germany by high voltage direct current more renewable energies in the grids is accepted by the (HVDC) transmission within a tunnel. The project is called general public, but there is still the “not in my backyard” OVANET – Overlay Grids as an Option for the Future. An (NIMBY) discussion for each electricity transmission route overlay grid can be understood as a meshed highway for the electricity transmission, which is laid in addition onto the 2212-8271 © 2016 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).

Peer-review under responsibility of the International Scientific Committee of the 13th Global Conference on Sustainable Manufacturing doi:10.1016/j.procir.2016.01.040

80 | 13TH GLOBAL CONFERENCE / GERMANY

already existing transmission grid to which it has only a certain amount of interfaces.

Considering only the transport and the installation of the cable, there are several difficulties which need to be taken into account. Today's solution for any kind of land cable is to use trucks for the transport to the point of installation. Taking into account that a truck is only capable of transporting 40 tons, a single length of a HVDC cable cannot extend – depending on the specific cable design – the limitation of 1 to 1.5 km.

Considering our case of a meshed electricity grid, a solution based on truck transportation would not only cause huge logistics costs, but would also have higher assembly costs due to the amount of necessary joints, which could also influence the failure rate of the connection. The assembly of joints requires highly skilled craftsmen, are not allowed to any mistake.

Another solution, which has to the best knowledge of the authors not been realized yet, is to carry the cable on ships directly towards an entry of a meshed long-length tunnel. A ship-based solution would due to the costs of the rental of a ship raise the logistics costs for the transport. Furthermore concepts would have to be developed how a cable handling could be realized, without damaging the cable. Both possibilities, a direct transport into the tunnel as well as an intermediate storage raise the possibility of a failure and bring further costs. Beside all costs, one natural limitation for this solution is given. A suitable entry to the tunnel close to the water with enough width and depth must be given by its location.

A third solution, which has also neither been planned nor realized yet, is a mobile or non-stationary cable factory which is designed to produce only the HVDC cables needed for this project and to conduct the cable directly into the tunnel.

Mobile is meant in the sense of movable to another spot after a certain production period. This approach allows eliminating the transportation costs from the factory to the tunnel to a minimum and at the same time to minimize the amount of joints needed. As already described each joint raises the total production costs, is time consuming and needs highly skilled craftsmen. So in addition, to reduce the costs of the current cable production and to make at the same time the idea of a mobile cable factory more attractive, approaches are developed to minimize the joints needed and to optimize the state of the art cable production.

Therefore, in this paper the challenges and approaches for a continuous cable production with a focus on extruded cables are shown.

2. HVDC cable production and its limitations Within the framework of the OVANET project cables for HVDC transmission with a 500 kV capacity are considered.

In recent onshore and offshore cable connections mass impregnated (MI) cables as well as cross-linked polyethylene (XLPE) insulated cables are deployed. Whereas long-term experience in operating MI cables is available, the more recent XLPE technology is promising less installation costs and has the potential to lower the production costs [5].

Regardless of the insulation type, the main components of

transmission cables, illustrated in Fig. 1, are similar throughout both technologies.

Fig. 1. Schematic representation of a HVDC power cable

2.1. Conductor The conductor of the HVDC cable has the main function to carry the designated electric current. It is made of copper or aluminum wire which is drawn to its specific diameter in the first step of manufacturing the conductor. Within the drawing process surface imperfections are removed from the round rods [6]. Copper has a three times higher specific conductivity than aluminum, thus the conductor and therefore the entire cable is smaller in diameter at similar performance.

Aluminum conductors are lower in weight and cost, even though more material is used. In the second step, the wire is stranded to a round shaped conductor with a size of 2000 to 3000 mm². Within the stranding process, the conductor is repeatedly compressed and smoothened by rolling mills to remove gaps. Fig. 2 shows the process of conductor production.

Fig. 2. Conductor stranding

The limiting factor for conductor production is determined by the wire lengths on the stranding machines drums. Total continuous lengths of 20 to 30 km have been reached for sea cable conductors so far [7]. According to the industry however, welding of single wires to achieve significantly longer conductors in a continuous process is merely a matter of production organization.

2.2. XLPE insulation and semiconducting screen The inner and outer semiconductor screens provide a smooth mechanical interface between conductor and insulation. This way, a homogenous electrical field throughout the insulation screen is achieved and local deviations of electrical stress are prevented. For XLPE insulated cables the semiconductor screens are composed of a

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similar compound to the insulation, enriched with conductive carbon black [8].

The insulation shields the high voltage potential of the conductor from the ground potential of the metal sheath. The thickness of the insulation layer is determined mainly by the electric field strength of the system. It is composed of XLPE compound. The XLPE granulate has to be handled with highest regard to purity and cleanness. Even minor imperfections in the compound can lead to an irreversible cable defect. To avoid any containment, void or gap at the interfaces, insulation, and inner or outer semiconductor screen, they are applied simultaneously by triple extrusion.

The extrusion process is not only a bottleneck for production speed but also the most critical process in regard to a continuous cable production. As part of the purity requirements of the insulation the molten XLPE compound streams through a number of extruder screens. These screens as well as the extruder have to be cleaned after the extrusion of 40 to 60 tonnes of cable insulation material [7]. According to information from the cable industry, the extrusion head needs to be cleaned after 100 tonnes of insulation material.

In a continuous process directly after extrusion and under the influence of peroxide, a chemical cross-linking agent, thermal energy and pressure the molten polymer is cured.

This step is not considered a limiting factor in regard to the continuous cable production. The process of XLPE insulation can be seen in Fig. 3.

has a relative moisture of around 8 % and has to be dried under controlled conditions for several days to contain less than 1 % of water [9].

As soon as this pre-treatment is finished the paper is wrapped around the conductor in the lapping machine which is again located in a humidity controlled environment. 100 to 200 layers of paper are applied with prescribed tensions taking into account mechanical strength and bending flexibility of the cable. To compensate imperfections of the organic paper material and to avoid paper edges stacking up in the same spot the tapes are overlapping [10]. The wrapping process may be interrupted to mount new paper rolls to the machine and does therefore not constitute a limitation in terms of a continuous cable production.

To increase the electric stability of the insulation it is dried further and impregnated in the next step of manufacturing.

The cable is placed in a vacuum chamber where it is subject to a decreasing water vapor partial pressure of 10 -2 to 10-3 mbar for around 14 days. To increase humidity diffusion out of the insulation the chamber is slowly heated to a maximum of 120 °C. When the insulations contains less than 0.1 % of water, the chamber is flooded with an impregnation mass [9].

This compound mainly consisting of mineral oil and resins has to be dried and degassed itself before being used for impregnation. So far, the drying and impregnation of the paper insulation is a discontinuous process. Possible production lengths are determined by the cable diameter and the size of the vacuum chamber.

2.4. Metal sheath

Fig. 3. XLPE insulation process [10]

The last step in XLPE insulation manufacturing is the degassing of cross-linking by-products. While these byproducts are held in during the curing process through external pressure to avoid pores in the insulation, they have to be degassed afterwards. This is performed under temperatures of no more than 80° C to prevent thermal damages and ageing of the insulation. Hence the process can take up to 28 days for larger HVDC cables, which would require for a continuous process more than 20 km of cable being continuously treated at the same time in consideration of operating speeds of state of the art extruders.

2.3. Mass impregnated and semiconducting screen The material for insulation as well as semiconductor screens for MI cables is paper tape. The semiconducting layers include carbon black but are otherwise treated and applied as the insulation itself. With indoor climate the paper

82 | 13TH GLOBAL CONFERENCE / GERMANY

The metal sheath serves as a radial water barrier and carries the ground potential. For both cable technologies (XLPE and MI) a solid metal sheath made of lead or aluminum is applicable. A lead sheath is produced as a tube around the cable by a Hansson-Robertson extruder, which is fed with molten lead. Continuous high quality sheaths of 50 km or more are possible [11]. Aluminum on the other hand is applied as sheet metal and connected by strip welding at the overlapping edges alongside the cable. In addition, sheets may be welded crosswise in order to manufacture longer cables.

Alternatively aluminum can be extruded as described for lead.

As there is no impregnation mass in XLPE cables, another option is very commonly used for these cables particularly for onshore connections. A polymer-coated aluminum foil of about 0.2 mm thickness is sufficient in preventing humidity intrusion into the cable. The so called aluminum laminate sheath is supplemented by an underlying wire screen to shield the electric field carry the ground potential and a possible short-circuit current. The wire screen is manufactured similar to the conductor stranding. The aluminum foil is glued at an overlap.

2.5. Oversheath The oversheath has the main function to protect the cable from mechanical damages. It further prevents water intrusion

Fig. 4. Cable production process

and corrosion of the metal sheath. Additionally other functions like fire protection may be integrated [12]. The oversheath consists of polyethylene and is extruded onto the cable. Since purity requirements are comparably low for this outer layer, production is not limited as for the XLPE extrusion. The process of the cable production is shown in Fig. 4.

2.6. Joints Power cables are connected by joints to increase their length. Multiple techniques for jointing are available. All of them start with connecting the conductor by welding or with mechanical connectors. MI cables are then insulated by manually lapping impregnated paper around the connection spot. This can be done in the factory as part of the production process or in the field as part of laying out the cable or during repair operations.

For XLPE joints techniques vary for factory environments and the field. Connecting cables in the factory is done by either lapping XLPE tape around the conductor similar to the paper insulation or by extruding XLPE into a mold around the connection spot. For field connections, prefabricated joints are deployed. These standardized joints are less costly and faster to install which are advantages over MI cables [11].

2.7. Testing All high voltage cables pass through different tests during development and after manufacturing. Performing electrical testing after production is limited to finite cable lengths of few kilometers though [9]. Additionally, these cables are subject to long-term trial phases after laying out the connections. The particular tests to be carried out as well as their extent are determined in agreements between network operators and cable manufacturers.

3. Contribution to a continuous cable production A reason for the actual limitation of land cable production is the difficulty of transportation. Furthermore, a land cable connection of more than a few hundred kilometers has not been realized before. The mobile cable factory allows the shortfall of the transportation of the cable. The idea is to have the factory close to the tunnel and being able to directly insert the cable. It also allows a reduction of joints by extending the single cable length further. So an additional cost reduction can be realized. After a certain period of time, the mobile cable factory will be transported to another position close to the tunnel were it will continue the production.

As elaborated before, various adjustments in the cable manufacturing process are required for a continuous production facility. So far separate production units have to be configured into a steady process flow. Whereas different operating speeds of machinery can be aligned, buffers are necessary to balance set-up times and failures. Furthermore, technical innovations for some processes are inevitable.

Approaches for the modification of two productions steps are shown in the following.

3.1. Triple extrusion For XLPE cables the extrusion presents a major limit to a continuous cable production. The extruder has to be cleaned after 40 to 60 tonnes of insulation material. The extrusion process cannot be paused for this matter.

A concept which allows the application of two extruders instead of only one to circumvent this limitation is shown in Fig. 5.

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4. Conclusion and outlook

Mustafa Severengiz et al. / Procedia CIRP 40 (2016) 18 – 23 Mustafa Severengiz et al. / Procedia CIRP 40 (2016) 18 – 23 Mustafa Severengiz et al. / Procedia CIRP 40 (2016) 18 – 23 Mustafa Severengiz et al. /4.Procedia CIRP and 40 (2016 ) 18 – 23 Conclusion outlook

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4. Conclusion and outlook 4.InConclusion outlook When the and first extruder is close its production limit, the this paper a future option for a to future HVDC overlay 4. second Conclusion and extruder isoutlook turned on. for During the run-up phase of In this paper a future option aisfuture HVDCwhich overlay grid within a tunnel-based solution introduced, is the Inwithin paper a its future option for isa introduced, future overlay grid a the tunnel-based which is a second extruder meltof issolution discarded through outlet until trying tothis meet demand the general public HVDC asanwell as the grid athe tunnel-based solution introduced, In within this paper ademand future option for aisadvantages future HVDC overlay trying to meet of The the general public as well as the steady flow at the target temperature is reached.

Before demand for grid expansion. main arewhich the inisthe trying toformeet the demand of the general publicthe as well as the grid a tunnel-based solution introduced, which is demand grid advantages are the in firstwithin extruder isexpansion. shut off, aThe valve isisshifting material flow comparison to overhead lines ormain underground cables easy demand for grid expansion.

The main advantages are the in trying to meet the demand of the general public as well as the comparison to overhead lines or underground cables easy to the second extruder. outlet invisibility behind the second extruder capacity expansion andThetheir by being comparison to overhead underground cables demand for grid expansion.

The main advantages theeasy in capacity expansion and lines their invisibility being underground. is closed while it is opened for or the first extruderby toare accomplish capacity expansion and invisibility byoradditional being comparison to overhead lines orsolution, underground cables easy underground. realizing the tunnel-based a head. mobile nonaFor constant material flow intotheir the extrusion An underground. capacity expansion and For realizing thebehind tunnel-based amixes mobile or being nonstationary cable factory in range ofsolution, theinvisibility tunnel, whichby allows a to extrusion screw the their switch valve both melts Forinsert realizing thecable, tunnel-based solution, mobile or and nonunderground. stationary cable factory in range the tunnel,a which allows direct of the can beofan approach to reduce thea the ensure a homogenous polymer insulation.

Cleaning stationary cable factory in range of the tunnel, which Forinsert realizing thecable, tunnel-based solution, a12 mobile or nondirect of extrusion the can betake an approach toproblem the transportation costs.

By eliminating the of a exchange of screens around toreduce 24 allows hours. direct insert of the cable, cable, can be an to reduce the stationary cable factory in range oflengths the approach tunnel, which allows a transportation costs.

By eliminating the problem of of the single of the cable can be Consultation with cable manufacturers and an extruder transportation costs.

By eliminating the problem direct insert of the cable, can be an approach to reduce the transportation the cable,the lengths thethe cable canand beof extended.

Thisof reduces of of joints needed manufacturer resulted insingle a amount confirmation of technological transportation the cable, lengths of cable can be transportation costs.

By eliminating theittherequires problem of extended.

Thisofof reduces the single amount of joints needed increases the cable reliability.

However an feasibility this approach.

However, special care and in the extended.

This reduces the amount of joints needed and transportation of the cable, single lengths of the cable can be increases the cable reliability.

However it requires an increased level process mastery for the transition cable factory.

The and design of theof valves to create a smooth of melts increases the cable reliability.

However it requires an extended.

This reduces the amount of joints needed and increased level offorprocess mastery for cable factory. main obstacles a continuous production are The the prevent any contamination has tocable be the taken. increased level of process mastery for cable factory.

The increases thedegassing cable reliability.

However it requires an main obstacles for a continuous production are the extrusion and process.

Forcable boththe processes solutions main obstacles a process. continuous cable production areThe the increased level offor process mastery theprocesses cable extrusion and degassing Forfor both solutions are shown, whose implementation would notfactory. enable a 3.2.

Degassing extrusion and degassing process.

For both processes solutions main obstacles for aimplementation continuous cable production are the are shown, whose would enable a continuous cable production, but a doubling of anot single length. are main shown, whose implementation would not solutions enable a extrusion and degassing process.

For both processes continuous cable production, but athese doubling of a optimizations single length.

The reason for been not having process Degassing has a discontinuous process so far.

Cables continuous cable production, buthas a doubling ofaanot single length. are shown, whose implementation would enable a The main reason for not having these process optimizations implemented yet, are that there not been project, that withmain lengths ofproduction, onenot to two kilometers are in heated The reason for having optimizations continuous cable but a these doubling of aatreated single length. implemented yet, are that there has been project, that requires longer single lengths.

But fornot theprocess OVANET project, chambers with space forhaving one cable drum. implemented yet, are that there has not been a project, that The main reason for not these process optimizations requires longer single lengths.

But for the OVANET project, this might a reasonable approach do to the very high demand Fig. longer 6 shows an that approach forfor a the heated chamber with a requires lengths.

OVANET project, implemented yet,single are thereBut has athere project, that this mightfor a reasonable approach do tonot thebeen very high demand of cable an onshore cable.

Furthermore, are no continuous degassinglengths. process.

The is designed similar this might reasonable approach dofortobuffer the very high are demand requires longer the project, of cable forawith an single cable.

Furthermore, there noa experiences aonshore mobile cableBut factory yet.OVANET Especially for to a turntable used in offshore cable manufacturing.

It differs of cable for cable.factory Furthermore, theredemand are this might of awith reasonable approach do to would the experiences a onshore mobile cable yet.very Especially for tono a realization theanOVANET project this be high necessary from a turntable by using fix layers which enable an improved experiences with a mobile cable factory yet.

Especially for of cable for an onshore cable.

Furthermore, there are noa realization of the OVANET project this would be necessary to reduce the transportation and joint costs and to increase the degassingofprocess. realization the project this would necessary experiences with aOVANET mobileand cable yet. for a reduce theoftransportation jointfactory costs and Especially tobeincrease theto reliability the cable.

Thethe cable isOVANET led into the chamber through annecessary air shower to reduce transportation and joint costs and to increase the realization of the project this would be to reliability of the cable.

Currently, the mobile factory alternative does raise many reliability of the cable. reduce the transportation and joint costs and to increase the Currently, the questions mobile factory alternative does raise many further crucial about the implementation of such an Currently, mobile factory alternative does the raise many reliability ofthe the cable. further crucial questions implementation of such an overlay grid, which are about beingthe discussed within project further grid, crucial questions about the ofdetailed such an Currently, thewhich mobile alternative raise many overlay are factory being discussed the project OVANET. Further research has to beimplementation done within ondoes a more overlaycrucial grid, which areabout being the project further implementation such an OVANET. Further has the todiscussed be done onwithin a more detailed approach of howquestions toresearch realize longer distances.

So far,of these are OVANET. Further research has discussed todistances. be done on more detailed overlay grid, which are discussed being the project approach of how to have realize longer Soafar, these are concepts, which we with the within cable industry.

In approachawhich ofcost how toresearch realize longer distances.

So far, are OVANET. Further done atomore detailed concepts, we have discussed with the on cable industry.

In addition, analysis hashas to to bebe developed see,these under concepts, which we have discussed with the cable industry. approach of how to realize longer distances.

So far, these are addition, a cost analysis has to be developed to see, under which circumstances the mobile cable factory is – spokenIn 6. we Rotating, 3-layer in degassing chamber addition, aFig. cost analysis has turntable to –cable bewith developed to under concepts, which have the cableis industry. which circumstances the discussed mobile factory –see, spoken from an economic perspective reasonable.

Besides, anIn which the mobile factory issee, –process spoken addition, aheat cost losses. analysis has tocan developed under prevent The cable is then stored spirally from ancircumstances perspective –becable reasonable.

Besides, an on increase ofeconomic single cable lengths only work ifto the from an –cable reasonable.

Besides, which circumstances the mobile factory is –process spoken multiple layerscable of perspective alengths rotating turntable.

Depending on increase of economic single only work ifwell the mastery cable production iscan increasing as and ananthe increase single cable lengths only ifBesides, thethe process from anof economic – 20 reasonable. anFor amount of layers aperspective diameter of to work 50 m is viable. mastery ofof cable production is can increasing astoday, well and an increase failure rate can be excluded.

Until idea mastery offailure cable production is increasing and increase cable lengths can only workas ifwell the process example asingle chamber with theexcluded. size of around 30 mnot diameter, increase ofof rate can be Until today, the ideaan a of a mobile cable factory for HVDC cables has been increase of therefore failure rate canweeks be unknown excluded.

Until today, the idea mastery of cable is increasing ashas well and an 0.5 of a mobile cableofproduction factory for HVDC not been residence time four and a cables production speed of realized and more yet difficulties may also of a mobile cable factory for HVDC cables has not been increase of failure rate can be excluded.

Until today, the idea realized and therefore more yet unknown difficulties may also m/s allows degassing in a continuous process with a capacity occur. realized and HVDC therefore more The yet unknown difficulties maybeen alsoand of mobile cable factory for HVDC cables hasis not occur. ofa 21 km cable. turntable which storing occur. realized and therefore more yet unknown difficulties may also releasing the cable at the same time has to be constructed in Acknowledgements occur.

Acknowledgements detail.

Acknowledgements We thank the German Federal Ministry for Economic Acknowledgements We thank the German Economic Affairs and Energy (BMWi)Federal for theMinistry funding for of the project We and thank German Ministry Affairs Energy (BMWi) Federal for for the funding offortheEconomic OVANET. Thetheresponsibility the content ofproject this Affairs and Energy (BMWi) forfor theMinistry funding of the We thank the German Federal for Economic OVANET. The responsibility the content of project this publication lies with the authors.

OVANET. The for funding the content this Affairs andlies Energy (BMWi) of the of project publication with responsibility the authors.for the publication lies with the authors.

OVANET. The responsibility for the content of this References publication lies with the authors.

References [1]References Cichowski R, Kliesch M, Merschel F. Kabelhandbuch. Frankfurt am Mai: References EW MedienR,und Kongresse, 2012. F. Kabelhandbuch. Frankfurt am Mai: [1] Cichowski Kliesch M, Merschel

gassing chamber en stored spirally on degassing chamber en stored spirally on e.

Depending on the egassing chamber hen stored spirally e.50Depending on For theon m is viable. ble.

Depending onFor the en spirally on 50 stored m und 30 is m viable. diameter, a ound 50 viable.

For le.

Depending on the 30mmis diameter, a oduction speed of 0.5 30 m viable. oround 50 m isspeed Fora oduction of 0.5 rocess with adiameter, capacity production speed ofand 0.5 ound diameter, a rocess with a capacity which30 ismstoring [2][1]Roland Berger StrategyM,Consultants: regarding grid infrastructure Cichowski R,–Kliesch Merschel Kabelhandbuch.

Frankfurt am Mai: process with a capacity roduction speed ofand 0.5 EW Medien und Kongresse, 2012. F.Study storing swhich to be is constructed in development: strategy for F. raising public acceptance.

European EW Medien und Kongresse, 2012.

[2] Berger –Kliesch Strategy Consultants: Study regarding grid infrastructure [1]Roland Cichowski R,European M, Merschel Kabelhandbuch.

Frankfurt am Mai: es to which is storing and process a capacity be with constructed in [2]development: Roland Berger –Kongresse, Strategy Consultants: Study regarding grid infrastructure European strategy for raising public acceptance.

European EW Medien und 2012. to be isconstructed in easwhich storing and development: for raising public acceptance.

European [2] Roland Berger European – Strategy strategy Consultants: Study regarding grid infrastructure as to be constructed 84in| 13TH GLOBAL CONFERENCE / GERMANY development: European strategy for raising public acceptance. European

In this paper a future option for a future HVDC overlay grid within a tunnel-based solution is introduced, which is trying to meet the demand of the general public as well as the demand for grid expansion. The main advantages are the in comparison to overhead lines or underground cables easy capacity expansion and their invisibility by being underground.

For realizing the tunnel-based solution, a mobile or nonstationary cable factory in range of the tunnel, which allows a direct insert of the cable, can be an approach to reduce the transportation costs. By eliminating the problem of transportation of the cable, single lengths of the cable can be extended. This reduces the amount of joints needed and increases the cable reliability. However it requires an increased level of process mastery for the cable factory. The main obstacles for a continuous cable production are the extrusion and degassing process. For both processes solutions are shown, whose implementation would not enable a continuous cable production, but a doubling of a single length.

The main reason for not having these process optimizations implemented yet, are that there has not been a project, that requires longer single lengths. But for the OVANET project, this might a reasonable approach do to the very high demand of cable for an onshore cable. Furthermore, there are no experiences with a mobile cable factory yet. Especially for a realization of the OVANET project this would be necessary to reduce the transportation and joint costs and to increase the reliability of the cable.

Currently, the mobile factory alternative does raise many further crucial questions about the implementation of such an overlay grid, which are being discussed within the project OVANET. Further research has to be done on a more detailed approach of how to realize longer distances. So far, these are concepts, which we have discussed with the cable industry. In addition, a cost analysis has to be developed to see, under which circumstances the mobile cable factory is – spoken from an economic perspective – reasonable. Besides, an increase of single cable lengths can only work if the process mastery of cable production is increasing as well and an increase of failure rate can be excluded. Until today, the idea of a mobile cable factory for HVDC cables has not been realized and therefore more yet unknown difficulties may also Mustafa Severengiz et al. / Procedia CIRP 40 (2016) 1 occur.

Commission Tender Acknowledgements

No. ENER/B1/2013/371. Revised Final Report, 2014.

[3] European Public Affairs: Not in my backyard! URL: We thank the German Federal Ministry for Economic http://www.europeanpublicaffairs.eu/not-in-my-backyard, June 2013. Last Affairs Energy (BMWi) for the funding of the project accessand February 22nd 2015.

OVANET. The Infrastruktur: responsibility for the fürcontent of this [4] ETG Task Force Stromübertragung den Klimaschutz – Potenzialelies undwith Perspektiven einer Kombination von Infrastrukturen. publication the authors.

VDE-Studie, 2011.

[5] De Alegría IM et al. Transmission alternatives for offshore electrical References power. Renewable and Sustainable Energy Reviews, 2009; 13: 10271038.

[1] R, KlieschPower M, Merschel F. Kabelhandbuch.

Frankfurt amPress Mai: [6]Cichowski Thue W. Electrical Cable Engineering.

Boca Raton: CRC EW Medien und Kongresse, 2012. & Francis; 2012.

Taylor [2] – Strategy Consultants: Study regarding grid infrastructure [7]Roland WorzykBerger T. Submarine Power Cables.

Design, Installation, Repair, development: for raising Springer; public acceptance.

European EnvironmentalEuropean Aspects. strategy Berlin, Heidelberg: 2009.

[8] Begovic MM. Electrical Transmission Systems and Smart Grids. Selected Entries from the Encyclopedia of Sustainability Science and Technology.

New York: Springer; 2013.

[9] Peschke F, von Olshausen R. Kabelanlagen für Hoch- und Höchstspannung. Entwicklung, Herstellung, Prüfung, Montage von Kabeln und deren Garnituren. Erlangen, München: Publicis MCD; 1998.

[10] Küchler A. Hochspannungstechnik. Grundlagen, Technologie, Anwendungen. Berlin, Heidelberg: Springer; 2009.

[11] Mazzanti G, Marzinotto M. Extruded Cables for High-Voltace DirectCurrent Transmission. Advances in Research and Development.

Hoboken: John Willey & Sons; 2013.

[12] Migliavacca G. Power Systems. Advanced Technologies for Future Transmission Grids. London: Springer; 2013.

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