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WIRE JOURNAL OCTOBER 2017
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CONTENTS
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Volume 50 | Number 10 | October 2017
Editorial . . . . . . . . . . . . . . . . . 6
FEATURE
Calendar . . . . . . . . . . . . . . . . 8 Industry News . . . . . . . . . . . 10 Industry Profile . . . . . . . . . . 20 Patent Report . . . . . . . . . . . 22 Asian Focus . . . . . . . . . . . . . 30 People . . . . . . . . . . . . . . . . . 32 Fiber Watch . . . . . . . . . . . . . 34 Fastener Update . . . . . . . . . 36 WAI News . . . . . . . . . . . . . . 38 Chapter Corner . . . . . . . . . . 42 Products . . . . . . . . . . . . . . . 60 Technical Papers . . . . . . . 70-83 Classified . . . . . . . . . . . . . . . 84 Career Opportunities . . . . . . 84 Advertisers’ Index . . . . . . . . 87
Next issue November 2017 • Plant Operations: Maintenance • Wrapups: IWCS wire Southeast Asia
Rising Hotshots . . . . . . . . . . . . 46 The wire and cable industry may be a mature industry, but one does not have to look far to see that it has its share of talented young professionals. This feature presents “a baker’s dozen” of profiles of individuals who have O F F I Cbeen I A L P Uidentified B L I C A T I O Nas O Fkey T H Eindustry W I R E A S Scontributors. OCIATION INTE A T I Oare NAL AR Nfew not that long out of college, while others have laid down more of a footprint. What they all have in common is that they have drawn attention in their niches: engineers, sales, a chemist, a maintenance manager, an entrepreneur and more. These are the kind of people that bosses love and colleagues depend on, each and every one well deserving of kudos. Consider this a long-overdue salute from a field that has a lot of room and opportunity for such rising hotshots.
TECHNICAL PAPERS Cycllic load effect on round strands made by twisted stracks of HTS N. Bykovsky, D. Uglietti, R. Wesche and P. Bruzzone . . 70 IWCS Paper: Implications of Higher Data-Rate Ethernet Over Prior Standard Twisted-Pair Data Cabling David C. Hess . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Cover: WJI’s first-ever class of Rising Hotshots honorees.
OCTOBER 2017 | 3
CONTENTS
INSIDE THIS ISSUE What comes after the flood
20
For CAP Technologies, Aug. 11-12, 2016 was a massive blow to the Louisiana-based company, which offers Electro Plasma Technology (EPT) for cleaning and coating metals. Horrible weather delivered floods that required its plant to be demolished and rebuilt. What followed was a challenging period, but it also became a time when CAP bolstered its focus on R&D. It developed its third generation of products, making advances not just in the apparatus it used, but to the process itself.
4 | WIRE JOURNAL INTERNATIONAL
Why do good employees quit?
52
The feature this issue presents profiles of a range of well-respected professionals in the wire and cable industry, but it also includes a Q&A with Peter Carino, principal of Wire Resources, Inc., a Connecticut-based recruiting firm. Carino, who has more than three decades of experience, talks about the industry’s search for young, bright people. He also has a second topic that should be of interest: why do companies sometimes lose such valuable staffers? His answer may surprise you.
EDITORIAL EDITORIAL
... and now for something completely different It may have nothing in common with the iconic 1972 Monty Python movie, but the feature in this issue does present a different look at the wire and cable industry: it’s not about trade cases, new equipment, an update on Industry 4.0, counterfeit products, consolidations or a slew of other everyday topics of concern. This time, it’s all about people, the focus on some of the individuals who are carrying the industry forward. The feature, WJI’s version of a “30 under 30” sector report, presents snapshots of 13 people from a range of wire and cable disciplines. While each person has followed a unique path, in a way, what matters is that each is part of the industry story. A recent survey by Deloitte and The Manufacturing Institute found that nearly eight in 10 Americans see U.S. manufacturing as being vital to the country’s economic prosperity. Those surveyed agreed that future manufacturing jobs will require high-tech skills (88%), will be clean and safe (81%) and will be more innovative (77%). And if you’re expecting a dark cloud to suddenly make an appearance here, you’d be right: for all the positives, fewer than three in 10 surveyed said they were likely to encourage their children to pursue a manufacturing career. Why the disconnect? In 1964, Marshall McLuhan, a Canadian philosopher and an icon in media theory, once said, “The medium is the message.” He believed that how information (the media) was exerted had a profound influence over people. Perception was increasingly being formed by the dominance of television/movies, which are simply viewed, whereas the printed word requires thought. One could only imagine how he would see the role today of the internet and the utter passion for smart phones. There is no single-turning point for manufacturing that one can point a finger at. It could be the result of millions of chiropractic-like electronic nudges the last three or four decades that infer that manufacturing is...lacking. The same Deloitte study stressed that there is hope for manufacturing, especially if the field is pro-active. A few of its recommendations include that companies: support further use of internships, apprenticeships and certification programs; invite the public to see what manufacturing actually is like today; and tap into under-represented demographic groups, including parents. The future of manufacturing continues to be written. In an electronic age, it’s especially hard to get that story across, but the essence of the profiles in this feature definitely deserve to be seen outside the field.
Mark Marselli Editor-in-chief
6 | WIRE JOURNAL INTERNATIONAL
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CALENDAR Nov. 1-3, 2017: CRU World Optical Fibre & Cable 2017 Wuhan, China. To be held at the Hilton Wuhan Optics Valley. Contact: CRU, tel. 44-207903-2000, www.crugroup.com.
Oct. 14-17, 2018: 67th IWCS International Cable & Connectivity Symposium Providence, Rhode Island, USA. To be held at the Rhode Island Convention Center, 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.
Nov. 27-29, 2018: Wire & Cable India Mumbai, India. This event will be held at the Bombay Convention & Exhibition Center. Contact: Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com.
Dec. 6-9, 2017: Iran Wire 2017 Tehran, Iran. This event, organized by the Aria Group, has a new date and location: the Exhibiran International Exhibition Center. Messe Düsseldorf is the exclusive overseas associate. Contact: Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com.
May 13-16, 2019: Interwire 2019 & WAI’s 89th Annual Convention Atlanta, Georgia, USA. This WAI event, which will be held at the Georgia World Congress Center, includes its trade show, technical programs and 89th Annual Convention, www.wirenet.org.
April 16-20, 2018: wire Düsseldorf 2018 Düsseldorf, Germany. This biennial event will be held at the Messe fairgrounds. Contact: Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com May 14-16, 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. Sept. 26-29, 2018: wire China 2018 Shanghai, China. The 8th All China International Wire & Cable Industry Trade Fair will be held at the Shanghai New International Expo Center (SNIEC). Contact: Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com.
WIRE ASSOCIATION INTERNATIONAL EVENTS May 14-16, 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,
8 | WIRE JOURNAL INTERNATIONAL
technical programs and 88th Annual Convention, www.wirenet.org. May 13-16, 2019: Interwire 2019 & WAI’s 89th Annual Convention Atlanta, Georgia, USA. This WAI
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INDUSTRY NEWS Leoni upgrades existing plant in Pune to take advantage of ‘Made in India’ Germany’s Leoni announced that the company has “enhanced” its location in Chakan, Pune, India, as part of its globalization strategy. A press release said that the company has inaugurated an electron beam accelerator that will allow it to provide high performance cables to customers from various industries such as railway or solar. “I am confident, that this major investment will contribute to the growth of our business in India,” said Bruno Fankhauser, a member of Leoni AG’s Board of Directors with responsibility for the Wire & Cable Solutions Division. “Thanks to the new technology, we are able to provide superior solutions for the country’s rising needs with regard to the initiative ‘Made in India.’”
Commemorating the news, l-r, are Florian Hettich, Leoni AG; G.K. Pillai, Walchandnagar Industries; Vinay Kumar, Greenko; Pushpendra Singh, Leoni India; and Jerry Cummins, Leoni AG. Leoni reports that it has invested more than €10 million into expanding its Pune location, which has seen the combined production area increase to more than 20,000 square meters, the release said. It added that the site, opened in 2013, now has the capacity to manufacture 80,000 km a year of electron beam cross linked cables. “This is the next phase of our evolution in India,” said Pushpendra Singh, managing director of Leoni Cable Solutions India Pvt. Ltd. “We began to develop this market in 2010 with an engineering office and a manufacturing facility for automotive wiring systems. ... We also have a strong foundation in the country with regard to special cables for dynamic industries like railway, solar, oil and gas, etc. Leoni’s new commitment will help us to further innovate and create beneficial solutions for India’s economy. The facility will drive synergies and economies of scale for our domestic operations as well as exports.”
Singh observed that India is witnessing tremendous growth in the solar and railway sectors. “This will definitely open up more opportunities for us since the need will be for cables of the highest quality benchmarks along with emphasis on safety,” he said. The additional capacity will help the company’s exports to neighboring regions such as Australia, Africa, the Middle East and South East Asia, Singh said. The Asia Pacific region currently contributes about 15-17% of the total sales of Leoni.
Prysmian and Telecom Italia extend partnership via 3 one-year contracts The Prysmian Group announced that it has renewed its partnership with Telecom Italia through three different one-year contracts for the supply of fiber optic cables and connectivity solutions. A press release said that the products for the contracts, to be used in the projects related to the Ultra-Broadband Digital Plan, is worth more than €33 million. Of that sum, €28.5 million is for cables, with the remainder related to the sale of joint boxes for optical cables and mini cables and modular optical distribution frames. The project is promoted by the Italian government, which working with the public and private sectors, seeks to fill gaps in infrastructure and services by 2025. “In this way, Italy will be able to achieve the objectives set in the Digital Agenda for Europe and create the conditions most favourable to integrated development of fixed and mobile telecommunications infrastructure.” The release said that the Prysmian Group will provide “the best and most innovative technical solutions, with a view to ensuring a faster and more reliable connection.” The traditional multi loose tube and mini loose tube optical cables will be produced at the Prysmian plants in Romania and Spain. The optical fibers used within them will be made at the company’s plant in Battipaglia (Salerno), where some 200 staffers produce nine million km of optical fiber a year.
The Prysmian Group will supply €28.5 million of cable for an ambitious Italian telecom initiative.
Got news? E-mail it to the WJI at editor@wirenet.org.
10 | WIRE JOURNAL INTERNATIONAL
Wire rod from Italy and Turkey found subsidized, but by a very small amount
The U.S. Department of Commerce (DoC) made an initial finding for three (Belarus, Russia and the UAE) of the 10 countries it is investigating for whether they dumped carbon and alloy steel wire rod in the U.S. market, and imposed antidumping duties (AD) of up to 756.93%. Yet to be resolved are the AD investigations of wire rod from Italy, South Korea, South Africa, Spain, Turkey, the Ukraine and U.K. In 2016, imports of carbon and alloy steel wire rod from Belarus, Russia and the UAE were valued at $10.4 million, $32.3 million and $7 million respectively, DoC noted in its statement. It found that exporters from Belarus sold products at 280.02% below fair value, those from Russia at 436.80% to 756.93% below, and those from the UAE at 84.10% below. One reason cited for those rates was a failure “...to provide responses to questionnaires.” U.S. customs authorities will collect duties from the exporters based on those rates. A final AD decision by the department was set for Nov. 21. The trade action followed petitions filed on behalf of Gerdau Ameristeel US Inc., Nucor Corp., Keystone Consolidated Industries and Charter Steel. Earlier this year, the U.S. International Trade Commission made a preliminary affirmative finding in the matter that sent the case to DoC for consideration.
The U.S. Department of Commerce made an affirmative preliminary determination in the countervailing duty (CVD) investigations of carbon and alloy steel wire rod from Italy and Turkey, but other than for one company that did not cooperate in its research, the subsidies were minimal. A press release said that the exporters received countervailable subsidies of exporters of subject merchandise from Italy and Turkey, receiving countervailable subsidies of 1.70 to 44.18% and de minimis and 2.27%, respectively. Of note, the 44.18% rate was set for Ferriera Valsider SpA, an Italian company, because of its failure to cooperate. In 2016, imports of carbon and alloy steel wire rod from Italy and Turkey were valued at an estimated $12.2 million and $41.4 million, respectively. Commerce is scheduled to announce its final determinations on or about Nov. 9, 2017, unless the statutory deadline is extended. Commerce also determined that critical circumstances exist in the Turkey investigation for certain exporters, allowing for collection of duties for a retroactive period of 90 days prior to publication of the preliminary determination in the Federal Register. The petitioners in the case are Gerdau Ameristeel US Inc.; Nucor Corporation; Keystone Consolidated Industries; and Charter Steel.
Wire & cable in the news...and this time it (kinda) glitters! Smuggling gold ‘a wire thing’ in India Smuggling gold into India has been on the rise, and sad to say, one method to avoid hefty Customs fees has been processing the precious element into wire. Below are some examples cited by various publications.
• A UAE man who turned 3 kg of gold into wire hidden inside a ceiling fan was detected at Sardar Vallabhbhai Patel International airport. • Two Bangkok men who were caught at Indira Gandhi International Airport had carried “kick scooters” that had 1 kg of gold springs hidden inside the handlebars. • Officials at Rajiv Gandhi International Airport caught a passenger who carried 467 grams of aluminum-coated gold wire that had been sewn into 12 bras. • A passenger arriving at Sanganer International Airport was found to have 700 grams of gold wire stashed in his baggage. • Officials at Rajiv Gandhi International Airport caught a man who had converted 1.25 kg of gold into thin wires and hidden it under straps of his trolley bag. • Customs officials at the Chandigarh International Airport recovered 540 grams of gold from a passenger who carried a suitcase that had beading made from wire used to form the suitcase’s internal structure.
An assortment of gold that has been transformed into different wire products for smuggling purposes.
• Two women were nabbed at the Indira Gandhi International Airport smuggling a kilo of gold in their bags that was made into wire and given a white coating (shown in above photos). A probe was to be done to see if they were carriers or part of an organized racket.
OCTOBER 2017 | 11
INDUSTRY NEWS
DoC makes initial finding for 3 of 10 countries accused of dumping wire rod
INDUSTRY NEWS
U.S.-based Redstone Machinery to rep for Italian steel mill equipment supplier U.S.-based Redstone Machinery, best known as a supplier of used steel processing equipment, announced that it has greatly expanded its scope through a recent agreement to represent Nuova Carpenteria Odolese (NCO), an Italian company whose scope includes turnkey rolling mills, in the U.S. and Canada. “This is a very busy and exciting time for us,” said Redstone Machinery President Jay Nyczak, who in 2003 founded his company in Plainville, Connecticut, after working a decade for Gavlick Machinery Corporation, where he was COO. “NCO is a relatively unknown company in North America, but they have been supplying world-class bar mill equipment for almost 50 years,” he said. “We are very interested in new projects, but also projects involving modernization, capacity increase, equipment replacement and refurbishing, as well as supply of tooling and other bar mill components,” Nyczak said. “For us to be given an opportunity to bid on all relevant projects, it is essential for industry executives and engineering management to know just what NCO is capable of, and that’s our focus now.” Per Nyczak, technology from NCO is used in more than 40 countries. The company, which has more than a hundred employees, can provide fully integrated services that include turnkey plants, auxiliary systems, and process development, process controls and automation for rolling mills for long products that includes bar, wire rod and small and medium sections. All equipment is built at NCO’s workshop in Odolo, Italy, which covers some 140,000 sq ft, and a designated NCO division supplies electrical and automation equipment for installations.
12 | WIRE JOURNAL INTERNATIONAL
NCO also provides design, engineering, installation, startup, production assistance, after-sales service, service and maintenance and spare parts. Nyczak can be contacted at tel. 860-747-2211, jay@ redstonemachinery.com, www.redstonemachinery.com.
TPC acquires Electra Cord TPC Wire & Cable Corp. has acquired Electra Cord, Inc., a manufacturer of custom power cords and cord sets, based in Massilon, Ohio, for an undisclosed amount. “The acquisition provides unique fabrication and manufacturing capabilities that will help us expand our product and service offering to OEM customers in key regions of the country,” TPC President and CEO Jeff Crane said in the release. Electra Cord, which supplies OEMs with different custom-molded cable assemblies, power cords, and cord sets, has 30 to 40 employees, said TPC Marketing Manager Annie Dorsey. There are plans to move them at some point, as well as the equipment, to TPC’s plant in Macedonia, Ohio, which is about 50 miles away. Before the acquisition, TPC had about 150 employees, she said. The company plans to expand the Macedonia plant by about 20,000 sq ft.
Prior to acquisition, TPC did not have a business relationship with Electra Cord (supplier, distributor, manufacturer, or otherwise), Dorsey said. With the acquisition of Electra Cord, TPC is well positioned to expand on current assembly capabilities and service to OEM customers by adding the select complementary products, equipment, and team expertise to support the broadened TPC operation. “A highly selective acquisition like Electra Cord is well suited to support TPC’s goal of enhancing service to OEMs in key markets.”
Italy’s Continuus-Properzi announced that two new plants, each capable of recovering 100% scrap with a copper content of 96%, will start production of Fire Refined High Conductivity (FRHC) rod in early 2018. A press release said that an 80-ton-per-day refining furnace, with annual capacity of 24,000 tons, is being installed at TLMZ LLC, in the region of Tolyatti, Russia. There, it will feed a new Properzi CCR line rated at 11 tons per hour. The second refining furnace will begin operation at Gil Rod Shomal Co. in Rasht, Iran, the release said. It will feature a recent patented design whereby the charging door is on the top and an automatized conveyor belt for loading the scrap into the furnace. The plant will have annual capacity of approximately 30,000 tons of 8 mm (FRHC) copper rod, using a Properzi System that currently works with cathodes to make ETP rod at a rate of 12.5 tons per hour. Copper rod from 100% scrap can fulfill the large majority of total tonnage required by the market as it can be drawn down to 0.25 mm wires and even smaller, the release said. It noted that FRHC rod was recently standardized by ASTM B4-15a as C11025.
Continuus-Properzi reports further deployment of its 100% scrap to FRHC rod technology. A half-century ago, Continuus-Properzi pioneered and promoted continuously cast and rolled copper rod. To date, it has sold nearly 60 CCR lines; half of which can produce FRHC or a combination of ETP and FRHC rod.
Prysmian completes supply of 35 km of power cable for Italy’s busiest port Prysmian Group reports that the company has completed the supply of 35 km of power cable for use in the expansion of the dry dock area in Italy’s Port of Genoa. A press release said that the 12/20kV MV cable, which included an aluminum cable and an optical fiber submarine cable with galvanized steel wire armor. The cables were produced in the Pignataro and Merlino plants and were customized to meet customer specifications.
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INDUSTRY NEWS
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INDUSTRY NEWS
The order came from S.I.C.I. Srl, an Italian company operating in the infrastructure and service sector through the distributor and Prysmian’s partner Majorano SpA. “For Prysmian Italia, this project marked a great result in terms of collaboration between our engineering offices and our production plants,” said Prysmian Italy Trade & Installers Sales Manager Maurizio Ciantra. “We worked with the customer to define the final specifications and requirements of the Prysmian cables. After the cable customization, which required a special consultancy process, our company successfully signed the contract, confirming its role as market leader.” The Port of Genoa is Italy’s largest host of shipping lines and final destination container handling.
Suit filed against state of Vermont to block order laying 550 miles of cable Comcast has sued the state of Vermont to try to avoid a requirement to build 550 miles of new cable lines in “un-cabled” areas, a requirement in its permit. Comcast filed suit against the Vermont Public Utility Commission (VPUC) in U.S. District Court. Per published reports, it challenged several provisions in the cable company’s new 11-year permit to offer services in the state. One of those requires Comcast to “construct no less than 550 miles of line extensions into un-cabled areas during the [11-year] term.” In its filings, Comcast claims that Vermont is exceeding its authority under the federal Cable Act while also violating state law and Comcast’s constitutional rights. That claim is not accepted by the VPUC, which notes that Comcast—which is the largest cable operator in Vermont—is simply attempting to avoid federal and state rules. Comcast said that the requirements will raise prices for Comcast customers. “Together, these contested conditions would impose tens of millions of dollars in additional regulatory costs and burdens on Comcast and its Vermont cable subscribers,” its papers declared. The commission, however, determined that the 550-mile buildout “will not impair Comcast’s ability to continue to earn a fair and
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KOCH order for drawing machinery is 1st one for a new welding wire niche A recent order for Germany’s KOCH stems from the company’s expansion of its OEM range of equipment to include a new segment of the welding wire industry. A press release said that while the company already is an established supplier to the welding wire industry, KOCH is now supplying a multiple-machine package
KOCH has expanded its welding wire technology to include stainless steel. to a new U.S. customer that will use it to manufacture stainless steel welding wire. That product, it said, represents a new niche for KOCH. The customer plans to use the systems for the automotive, agriculture, and nuclear industries. KOCH Managing Director Thomas Voss said that an order was for five new machines, one of which is a sixdraft model for flux-core wire. The new model had per-
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Report: optical cable market to see very large growth out to the year 2022 A report from Allied Market Research projects that the global market for active optical cables (AOCs), estimated
at $481.3 million in 2015, should reach $3.48 billion by 2022. A press release said that the report, which covers the period from 2016 to 2022, shows a compound annual growth rate of 32.7%. The “fresh” report looks at the market, including drivers such as demand for higher bandwidth, growing demand for active optical cable in data centers, a shift of the telecom sector toward faster optical networks and investment of government to improve connectivity. The report notes that advances in fiber optics technology can boost market growth, the challenge being that there are high initial investments to install active optical cable and challenges from optical network security fiber hacking. The report is segregated on the basis of connector, product application and protocol for related products, which are used for data center, high performance computing, personal computer, digital signage, consumer electronics, and in other sections such as transport, medical, airport, aircraft and ships. “Topics of market trends, growth, and opportunities, size and forecast have been touched on for each of the (segments),” it said. The report covers areas of North America, Asia-Pacific, Europe, and LAMEA, with key market trends, growth, and opportunities, size and forecast have been highlighted. For more information on the updated report, go to www.alliedmarketresearch.com.
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Chinese company sues Apple for alleged ‘unfair competition’ A Chinese electronic parts maker has filed a lawsuit against Apple, claiming that a mandatory certification program from the Cupertino, California-based technology giant is a form of “unfair competition” in the data cable market. A story in South China Morning Post spelled out why Pisen—known for its tech product accessories such as data cables, power plugs, and power banks—went to the Beijing Intellectual Property Court, which has accepted the lawsuit. The Shenzhen firm is demanding that Apple stop its “unfair” trade practices and is seeking 1 yuan as nominal compensation for economic losses. Basically, Pisen—which claims to be China’s second largest data cable manufacturer—can offer products such as cables that are as good as Apple’s but at far less cost, the report said. Pisen was described as “a popular brand on the mainland because of its low price compared with certified products sold via Apple’s official channels.”
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China’s Pisen wants to be able to offer customers a cheaper alternative to some Apple products. with its products. In its court filings, Pisen said Apple has repeatedly claimed that Pisen infringed Apple design patents obtained in Europe, which resulted in the removal of Pisen products from these platforms. Pisen counters that its application for MFi certification has been dismissed “many times,” and that Apple is using its dominant position in the market to disrupt fair competition. “Apple is one of the greatest companies in the world. But great companies should not do things that are harmful to the interests of consumers,” Pisen’s Chairman Zhao Guocheng said in a statement. “It is common for mid-and-small Chinese accessories makers not to join the MFi program as the cost for certification is very high, but it is rarely seen for big companies like Pisen which has frequently applied but has failed to obtain certification,” Zhao told the South China Morning Post, adding that he was puzzled as to why Pisen has not been successful in gaining certification. Apple said it has not responded to the lawsuit filed by Pisen.
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INDUSTRY NEWS
At its Tmall online shop, a Pisen standard data cable for Apple products is priced at 24 yuan ($3.60), inclusive of postage, with sales of more than 60,000 units in August alone. The company said it offers a refund for any reason within 30 days of purchase, and a free replacement within a year if there are product quality issues. At the official online Apple Store, the price of a standard data cable for the iPhone starts from 149 yuan, while a MFi certified Belkin data cable costs 228 yuan. Pisen claimed in a statement that Apple’s MFi mandatory certification does not make products safer, but it has damaged fair competition in China’s electronic components market. The story said that Apple’s MFi program, short for “made for iPod/iPhone/iPad,” charges high fees to certify that third-party electronic accessories will work
INDUSTRY NEWS
UL warns that Cat. 5e cable carries improper mark, may pose safety risk
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Underwriters Laboratories (UL) reports that a communications cable made by a Chinese manufacturer does not meet UL standards and has no right to bear its mark. A press release said that the Cat. 5e cable, type CMP, made by Nantong Lianxin Wire & Cable Co., Ltd., does not meet the flammability requirements of the safety standard which may cause an increased risk of fire. The 1,000-ft-long, solid bare copper cable, which carries the UL mark, is known to be distributed to companies by www.tekete.com, and may have been sold by other suppliers as well. The surface of the cable displays the UL image of a suspect Cat. 5e following: LOGICO cable package. E328429 CMP (UL)
Verizon Communications wants to exit some of its fixed line copper networks Verizon Communications has requested for federal regulatory permission to “retire” its fixed line copper networks in selected markets next year. Per press releases posted at the website of the Federal Communications Commission (FCC), on Sept. 7, its Wireline Competition Bureau (WCB) has been asked by Verizon for an okay to cease maintaining copper facilities in certain locations in eight states: Virginia, New York, New Jersey, Pennsylvania, Rhode Island, Massachusetts, Maryland and Delaware. The WCB’s mission is to foster competition in the provision of telecom services. Each request to the WCB states the same intention: “Verizon plans to retire a number of copper facilities and replace them with fiber facilities to provide services over its ‘fiber-to-the-home’.” If approved, the switchover could take effect on or after 28 February 2018. Earlier this year, four similar requests have been filed for certain locations in Texas, New Hampshire, Alaska, Florida, Ohio and Wisconsin.
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18 | WIRE JOURNAL INTERNATIONAL
INDUSTRY PROFILE PROFILE
After the flood: CAP Technologies DENHAM SPRINGS, LOUISIANA, USA FOCUS
CAP Technologies (CAP), founded in 2001, was originally located on the campus of Louisiana State University, and following several moves re-located to Denham Springs in 2011. The company has focused on Electrolytic Plasma Technology (EPT) that it reports offers superior ductility, which in turn allows for greater drawing speeds. In 2011, CAP began the transition from R&D to commercial production. CAP began production at its 50,000-sq-ft facility, there in 2013, with no idea that meddling weather gods had plans for a future visit.
OF NOTE
Ironically, the mass flooding—that claimed 13 lives, shut down CAP Technologies and was later called the worst U.S. natural disaster since Hurricane Sandy in 2012—did not get a storm name, even though it dropped the equivalent of 7.1 trillion gallons of water. The flood indirectly left a silver lining as the company used the rebuilding period to further its product development. It entered its third generation of process technology, and multiple patents have been filed. www.captech nologiesllc.com
CAP Technologies took a knockout blow from devastating floods in Louisiana in August 2016, but the company rebuilt and emerged as a better, stronger entity. The water that inundated its facility later proved to be beneficial. Below, company President Edward Daigle explains. WJI: First, what does your company do? Daigle: Our CAP Technologies process, (EPT), uses only electricity and benign electrolytes to clean and coat metals. It offers manufacturers an environmentally friendly option to using strong acids that are very harsh. Besides being environmentally friendly, our EPT process reduces/eliminates the need for toxic materials handling, storage and disposal. WJI: A little more than a year ago, your company was flooded by more than four feet of water: what happened, and how did your company deal with the aftermath? Daigle: On Aug. 11-12, we took what was considered by many to be a knockout blow from devastating floods at our plant in Louisiana. We could not return to the plant until August 16, after the water receded. In the days that followed, our employees, family and friends all pitched in to start the clean-up and demolition of the offices and plant. Within a month we had the offices back in working order and the plant offices, breakrooms and restrooms repaired within eight weeks. Because the electro-plasma process is primarily an electrical process, naturally water and electricity do not mix, and therefore extensive damage occurred. The primary equipment are the DC rectifiers, and most were not repairable, therefore new rectifiers had to be ordered. Delivery times were eight to 10 months. New rectifiers were recently installed. Now we plan to replace all second generation reactors with newly designed third-generation reactors. WJI: We heard there was a silver lining to your situation: what was that? Daigle: We didn’t set out to do this, but before the flood took place we
20 | WIRE JOURNAL INTERNATIONAL
were working with wire to determine the results of our EPT applied coatings. We had used some 5.5 mm wire rod a week or so before the flood. When we processed the rod, we applied 8 µm of zinc, and then drew it down to 2.04 mm. This allowed us to proportionally reduce the coating thickness to about 2.5 µm. That spool of wire laid on the plant floor for over four months in varying temperature ranges from 30-1100°F, with humidity levels in excess of 90% at times. When the area received 32.5 inches of rain in a 36-hour period, the Amite River overflowed its banks and our plant took in more than four feet of water. That particular spool of wire was well below the water level, and it stayed submerged there for approximately three days until the water finally receded. The spool was left there while a lot of other work was ongoing. That wire showed no signs of rust after four months, proof indeed that we had something good. WJI: How did your recovery progress? Daigle: After approximately five months we were able to get the intermediate and fine wire lines operational and the main line only partially operational. During this time, significant advances to the technology were made, not only to the apparatus but much of it to the process itself. These advances would not have occurred as quickly or not
CAP Technologies President Edward Daigle rebounded from a natural disaster that had devastated the company’s plant.
PROFILE From l-r at CAP Technologies: Don Koshier, sales; Edward Daigle, president; Richard Webb, wiredrawing; Yantze Jackson, plant manager; Chris Bearden, production; Mark Jackson, maintenance; Blythe Daigle, office manager, Chris Gilmore, production manager; Larry Padfield, board member; and Glenn Giviens, production. at all had the flood not occurred. As CAP rebuilds over the coming months, the installation and application of the third generation process and apparatus will be readily visible in our ability to produce products. WJI: What are examples of what you can do now that you couldn’t prior to the flood? Daigle: CAP has greatly expanded the range of potential coatings we can provide. We now have applied 33 different single metals, layered metals, and alloys. We are now working with several companies to create and deposit coatings that can only be described as exotic on various substrate materials. Besides coatings, EPT provides opportunities for surface texturing as well as cleaning any surface contaminant. WJI: Are most of these commercialized? Daigle: Most are. CAP recently installed the first of these cleaning units for a customer and we got a strong indications that two more units will be ordered. Four major companies have requested quotes on rod processing lines, for cleaning mill scale and coating, two in the U.S. and two in other countries. The benefits of the EPT process are primarily that no metallurgical changes occur during processing, unlike the hot dip coatings that change
metallurgical properties that most of the time require additional processing. Tensile strengths of 400 Ksi and greater have been achieved from the direct drawing from EPT coated rod and unlike hot dip coatings, no intermetallic is formed. Possibly the most unique aspect of an EPT applied coating is the ductility. In trials, something unique happens. For forming, there is less downtime and cooler operating temperatures even at higher forming rates. In recent trials, several sizes of high carbon wire rod cleaned (mill scale) were coated by the EPT process and drawn. In each case, drawing speed increased from 15% to 30% faster, and die and block temperatures were on average 50 degrees cooler then at slower drawing speeds with zinc phosphate, and eliminating that hazardous material is another benefit. WJI: Where do you go from here? Daigle: This is an exciting time for CAP. We have requests for quotes on major cleaning and coating lines from several areas of the world as well as for cleaning only lines. A year and a few months ago, we were in a dismal water-logged state, and now we have new ideas, new equipment, new enthusiasm and a long-time-held belief that our future is bright.
OCTOBER 2017 | 21
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. Wire harness U.S. Patent No.: Patent date: Assignee: Inventors:
9,755,410 Sept. 5, 2017 Filed: Aug. 11, 2009 Yazaki Corporation, Japan Hidehiro Ichikawa, Tatsuya Oga, Takeshi Ogue [Problem] To provide a wire harness allowing a relatively large number of electrical wires to be passed under the floor of a vehicle body. [Means for Solving Problem] A wire harness is provided with a plurality of high-voltage electrical wires, a protection member which protects the high-voltage electrical wires, fixed members which fix the wire harness in a vehicle, and a low-voltage electrical wire. The protection member has two protection members for body under floor and a body under floor protection member. The protection members thereof are flat-corrugated tubes. In the two protection members for body under floor protection member, circuits which have the plurality
of high-voltage electrical wires are respectively received. Also, in the protection member for body under floor, a circuit which has the low-voltage electrical wire is received. The two protection members and the protection member are arranged side by side.
Copper alloy wire rod and method for manufacturing the same U.S. Patent No.: 9,754,703 Patent date: Sept. 5, 2017 Filed: March 19, 2014 Assignee: NGK Insulators, Ltd., Japan Inventors: Akihisa Inoue, Hisamichi Kimura, Naokuni Muramatsu A copper alloy wire rod includes a copper parent phase and short fiber-shaped composite phases which are dispersed in the copper parent phase and which contain Cu.sub.8Zr.sub.3 and Cu, wherein the content of Zr is within the range of 0.2 atomic percent or more and 1.0 atomic percent or less. This copper alloy wire rod can be obtained by including the steps of melting a raw material in such a way that a copper alloy having a Zr content within the above-described range of is produced so as to obtain a molten metal in a melting step, casting the molten metal so as to obtain an ingot in a casting step, and subjecting the ingot to cold wire drawing in a wire drawing step, wherein the wire drawing step and a treatment after the wire drawing step are performed at lower than 500.degree. C.
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Stainless steel flux cored wire U.S. Patent No.: 9,751,158 Patent date: Sept. 5, 2017 Filed: July 21, 2015 Assignee: Kobe Steel, Ltd., Japan Inventors: Tetsunao Ikeda, Hiroshi Sugahara, Hirohisa Watanabe
In a stainless steel flux cored wire comprising a stainless steel shell and a flux filling the shell, the amount of Si contained in the entire wire is 2.5% by mass or higher, preferably 3.0% by mass or higher in terms of SiO.sub.2, and the amount of at least one compound selected from the group consisting of polytetrafluoroethylene, graphite fluoride and perfluoropolyether contained in the flux is 0.005 to 0.10% by mass of the total mass of the wire in terms of F, preferably 0.020% by mass or higher. By employing such a constitution, in welding of Cr--Ni-based and Cr-based stainless steels and other materials, fume generation and hexavalent chromium leaching can be significantly reduced, and excellent welding workability can be provided.
Mechanism of small drive wire retention on spool U.S. Patent No.: 9,750,397 Patent date: Sept. 5, 2017 Filed: May 27, 2015 Assignee: Cook Medical Technologies LLC, USA Inventor: Michael Lee Williams A steering mechanism for a medical device that is configured for passing through the body cavities of a patient and for passage through an endoscope working channel is described. The mechanism comprises at least one spool having a central hole through which a central axle passes, the spool being rotatable about the axle, and the spool hav-
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OCTOBER 2017 | 23
PATENTS
Multimode optical fiber and optical cable including the same U.S. Patent No.: 9,753,216 Patent date: Sept. 5, 2017 Filed: Aug. 27, 2015 Assignee: Sumitomo Electric Industries, Ltd., Japan Inventors: KazuhiroYonezawa,Tadashi Enomoto An embodiment of the invention relates to a MMF with a structure for enabling stable manufacture of the MMF suitable for wide-band multimode optical transmission, for realizing faster short-haul information transmission than before. In the MMF, when an input position of a DMD measurement pulse on an input end face is represented by a distance r from a center of a core with a radius a, a power of the DMD measurement pulse on an output end face with the input position r of the DMD measurement pulse being 0.8a is not more than 70% of a power of the DMD measurement pulse on the output end face with the input position r of the DMD measurement pulse being 0.
PATENTS
ing at least one retaining tube having a lumen therethrough and configured to contain a portion of a drive cable. The drive cables, which may include UHMWPE, are capable of and are effective for deflecting the distal end of a catheter or endoscopic device, while preferably each being at least partially disposed through a retaining tube that is effective to prevent tangling or other binding of the cable(s).
Signal transmission cable U.S. Patent No.: 9,748,748 Patent date: Aug. 29, 2017 Filed: Aug. 16, 2011 Assignee: Southwire Company, LLC, USA Inventor: Lucien Ducret A blade stripper has a displaceable blade carriage, which is normally biased toward a cable support to automatically accommodate differently dimensioned jacketed cables in a desired position. The blade carriage supports a blade assembly configured so that the blade can be displaced among multiple positions corresponding to respective axial, radial and a plurality of spiral cuts while the cable is engaged in the desired position.
Active cable U.S. Patent No.: 9,748,696 Patent date: Aug. 29, 2017 Filed: June 10, 2015
Assignee: Hitachi Metals, Ltd., Japan Inventors: Kei Nishimura, Izumi Fukasaku, Takahiro Sugiyama An active cable that is capable of reducing crosstalk is provided. A ground pattern is formed so as to sandwich one or both of a part of a transmission side transmission channel located at a side closer to the other side than a compensation circuit and a part of a reception side transmission channel located at a side closer to the other side than the compensation circuit.
Semi-solid balanced audio cable U.S. Patent No.: 9,748,022 Patent date: Aug. 29, 2017 Filed: Aug. 24, 2016 Assignee: Belden Inc., USA Inventor: Galen Gareis Audio cables including a conductor spirally wrapped in a non-conductive thread to centrally position the conductor within a channel comprising mostly air include a first conductor having a first diameter, and a non-conductive thread spirally wrapped around the center conductor, the non-conductive thread having a second diameter. A first jacket surrounds the center conductor and thread, having an inner diameter approximately equal to the first diameter plus twice the second diameter. A second conductor surrounds the first jacket and/or the center conductor and
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PATENTS
thread. In many implementations, the first diameter is less than the second diameter. A radially symmetric filler comprising a plurality of arms may form a corresponding plurality of channels.
Hybrid optical fiber ribbon and power cable U.S. Patent No.: 9,746,630 Patent date: Aug. 29, 2017 Filed: Jan. 14, 2016 Assignee: Corning Optical Communications LLC, USA Inventor: James Arthur Register III A hybrid cable includes a jacket defining a cavity therein, a central strength member, a ribbon unit having a plurality of optical fibers, and a conductor cable, wherein the conductor cable and the ribbon unit are stranded around the central strength member to extend through the cavity of the jacket. A method of manufacturing a hybrid optical and power cable includes stranding at least one ribbon unit and at least one conductive power cable around a strength member and extruding a jacket around the stranded at least one ribbon unit and at least one conductive power cable.
26 | WIRE JOURNAL INTERNATIONAL
Fiber-bundle assembly for maintaining a select order in an optical fiber cable U.S. Patent No.: 9,746,629 Patent date: Aug. 29, 2017 Filed: Nov. 10, 2016 Assignee: Corning Optical Communications LLC, USA Inventor: Gary Richard Trott A fiber-bundle sub-assembly includes an array of fiber bundles each having at least one optical fiber. The fiber bundles have select relative positions in the array. The sub-assembly includes first and second connecting elements that run along the array and that are secured to axially staggered top and bottom anchors to define first and second connecting spans that cross first and second sides of the array, with the first and second sides defined by first and second sets of fiber bundles. The first and second connecting spans are respectively attached to the first and second sets of fibers bundles to maintain the select relative positions of the fiber bundles even when the connecting spans are cut near one of the anchors during processing. A loose-tube cable that includes the fiber-bundle sub-assembly and a method of connectorizing the fiber bundles while maintaining their select positions are also disclosed.
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Data cable for high-speed data transmissions U.S. Patent No.: 9,741,469 Patent date: Aug. 22, 2017 Filed: Jan. 25, 2017 Assignee: Leoni Kabel GmbH, Germany Inventors: Bernd Janssen, Melanie Dettmer A data cable for high-speed data transmissions includes at least one wire pair formed of wires extending in a longi-
tudinal direction and being surrounded by a shielding foil to form a pair shielding. A dielectric intermediate film or foil having a varying lay length is spun around the wire pair between the shielding foil and the wire pair, in order to effectively avoid a damping peak at high transmission frequencies.
Power cable filler device and power cable comprising the same U.S. Patent No.: 9,741,468 Patent date: Aug. 22, 2017 Filed: April 9, 2014 Assignee: ABB HV Cables, Switzerland Inventors: Armando Leon-Guarena, Andreas Tyrberg, Lisa Johansson A power cable and filler device adapted to bear against a first and second power cores in a power cable, including a first arced wall which defines a portion of a first circle having a first diameter, a second and third arced wall, each defining a portion of a second circle having a second diameter which is smaller than the first diameter. A chamber is formed between the first, second and third arced walls.
(section cont’d. on p. 66)
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PATENTS
Cable with an integrated coiling and reinforcing wrapper U.S. Patent No.: 9,741,473 Patent date: Aug. 22, 2017 Filed: Sept. 30, 2015 Assignee: BBY Solutions, Inc., USA/Taiwan Inventors: Matthew Hess, Joseph Tseng, Kris Verstockt, Hsu; Hui-Hsiu Hsu, Daowu Ye The present invention is a cable, which carries signal, having an integrated coiling and reinforcing wrapper. The cable has a segment near an end that is stiffer than the cable generally. This segment can be bent by hand, and once bent, will retain its bent shape. If the flexible part of the cable is wrapped into a coil, or otherwise gathered together, then the stiffer portion can be bent around the gathered portion to secure it in its gathered form.
ASIAN FOCUS
ASIAN FOCUS ADB Outlook: South Korea
of access to the U.S. markets for goods originating in Mexico, causing losses for ROK firms that invested in Earlier this year, the Asian Development Bank released Mexico for its easy access to the U.S. market. These a report, Asian Development Outlook 2017, that presents investments grew to $5.5 billion annually in 2015. assessments of countries in Asia. This section will present The persistent ROK trade surplus with the U.S., which excerpts on some of the key countries—outside of China— has exceeded $20 billion every year since 2013, could through year’s end. The below overview of South Korea place the KORUS Free Trade Agreement (FTA), concludwas written by Gemma Esther Estrada and Donghyun ed between the U.S. and the ROK in 2012, among those Park of the EconomicResearch and Regional Cooperation targeted for renegotiation. The FTA eliminated 95% of Department, ADB, Manila. the tariffs between the two markets and created additional protections for financial and other service firms. The South Korea KORUS FTA is the largest FTA the U.S. has in Asia and one of the two largest for the ROK, the other being with Economic growth accelerated marginally to 2.7% in the European Union. Given substantial opposition to the 2016 from 2.6% in 2015, driven by strong expansion FTA before it was agreed—not only from U.S. firms but in consumption expenditure. Consumption increased also on the ROK side, notaby 2.8% and contributed 1.8 bly from farmers—renegopercentage points to growth, tiation could spell the end mostly reflecting faster of it. growth in private expenditure. A preliminary empirical Stimulus measures including analysis found that annual tax discounts for car purchases ROK exports to the U.S. helped lift consumer spending would fall by as much as in the first half. Then, under$13 billion from 2017–2020 mined by a political crisis —with a cost of 127,000 and subdued employment jobs in the ROK—if the prospects, consumer sentiment KORUS FTA collapsed. The plunged to a seven-year low in PEOPLE’S REPUBLIC OF CHINA average yearly export loss November, causing growth in HONG KONG, CHINA of $3.3 billion equals 5% of consumer spending to soften ROK exports to the U.S. in in the second half. The unemREPUBLIC OF KOREA 2016. Further, a 10% drop ployment rate rose to 3.7% MONGOLIA in the PRC exports to the from 3.6% in 2015 with the TAIPEI,CHINA U.S. would cause a 1.5% first falloff in manufacturdrop in ROK exports to the ing employment since 2009 PRC. The combined impact and further job losses as the of restrictive policies targetshipping and shipbuilding industries endured corporate ing the ROK and the PRC would lower ROK export prorestructuring. ceeds by $5.2 billion, or 1% of the total in 2016. As the U.S. is an important export market, taking 13.4% Effectively meeting the potential challenge of U.S. polof ROK exports in 2016, a more restrictive trade policy icy uncertainty requires three sets of policies. First, govthere could have major adverse implications. The number ernment and industry can take preventive action together of U.S. trade measures recently targeting ROK exporters to reduce trade friction and prepare for any policy change totaled 2,025 before the latest U.S. election, so any hint that nevertheless materializes. To this end, the governof further U.S. policy change heightens concerns for the ment announced in late January plans to expand imports ROK economy. from the U.S. However, industries that are likely to be hit The most immediate and direct impact of U.S. policy hard by annulment of the KORUS FTA, such as autos, change would be felt through lower exports to the U.S. electronics, and machinery, should prepare strategic conHowever, ROK firms may be hurt indirectly by new U.S. tingency plans to comply with possible new trade regulapolicy change against other countries. Most crucially, tions and develop new export markets. trade friction between the U.S. and the PRC would crimp Second, policy makers should closely monitor domesROK exports to the latter, which are mostly intermeditic financial market instability associated with mounting ate goods used in products that the PRC assembles and uncertainty regarding U.S. trade and other economic exports to the U.S. Further, the impending renegotiation policies. In light of the highly open capital account in the of North American Free Trade Area agreement with ROK, potentially volatile foreign capital flows are of parCanada and Mexico could restrict or increase the cost
EAST ASIA
30 | WIRE JOURNAL INTERNATIONAL
ASIAN FOCUS The above chart, from www.heritage.org, shows the overall ranking for South Korea in terms of economic freedom. ticular interest. The ROK has adequate buffers to mitigate the impact of large capital outflows, but the authorities must be prepared to act promptly to dispel any concerns about the balance of payments. Third, ROK policy makers can actively explore ways to extend the two countries’ robust security alliance into the
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OCTOBER 2017 | 31
PEOPLE
PEOPLE Mount Joy Wire has named Matt Graham as the company’s new process engineering manager, responsible for processing and internal quality and supervising the company’s process control manager and environmental service technician. He joined the company in 2009 as an environmental process engineer, and in 2015 served as Graham interim quality manager and as an understudy for the process engineering manager’s position. He holds a B.S. degree in chemistry and a minor in physics from Millersville University. Adam Dent was named the new quality assistant, responsible for managing quality complaints and customer quality issues and supporting internal quality control. He holds a B.S. degree in chemistry from Millersville University. He was awarded a Neimeyer-Hodgson grant to conduct collaborative research with ITT Engineered Valves, Lancaster. He also worked as a lab technician for Millersville and K&L Plating. Based in Mount Joy, Pennsylvania, USA, Mount Joy Dent
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Wire manufactures specialty wire for a wide variety of applications. Earlier this year, WAGO promoted Toby Thomann to president of North American headquarters. He has worked for company for 23 years in key positions, most recently, vice president of sales. He previously worked in international sales for Furon’s Dekoron Division for six years. He holds a B.S. degree in marketing/marketing management Thomann from The University of Akron. The company also reported that Andy Chesla has joined its sales force, covering Southern Minnesota and South Dakota. He previously worked for 10 years in different sales positions for Power/mation. He holds a B.S. degree in mechanical engineering from the University of Minnesota. Based in Germantown, Wisconsin, USA, the company is part of WAGO, a global supplier of spring pressure connection technology, based in Minden, Germany, with Chesla offices in over 80 countries.
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FIBER WATCH
FIBER WATCH Australian project to deploy country’s largest such ever FO cabling solution With an existing network of fibre optic cabling set to become collateral damage during construction works on Canberra’s Stage One Light Rail project, an Australian manufacturing plant has stepped up to create an entirely new, cabling solution—the largest ever to be manufactured in Australia—that will significantly improve the network’s current capacity to provide secure communications between Canberra’s federal government departments. Prysmian Australia CEO Frederick Persson said in a press release that the government body, ICON which manages the more than 1,000 km of government network of fibre optic cables, was looking for a faster, reliable and more cost-effective solution to replace the current assortment of standard, loose tube and various density cabling that stretches along the 12 km Stage One Light Rail path. “Since the launch of the Flextube® line in Dee Why, the plant has significantly improved the manufacturing and capabilities processes enabling us in Australia to produce a 1248 fiber cable,” Persson said. He observed that the Flextube technology is often chosen by carrier customer in Australia as the cable is lighter and more flexible with an innovative micromodule design “that’s faster and easier to install, increases duct capacity, reduces civil costs, is
34 | WIRE JOURNAL INTERNATIONAL
Prysmian’s Flextube® fiber. immune to kinking, gives easier access to fibres because you can remove the module material with no tools, and has better thermal stability.” Prysmian custom-made a Flextube offering with the perfect fiber count for ICON, 1248F, which will also be the largest cable product ever manufactured in Australia, the release said. “Because we’re a local company, based in Dee Why near Sydney, we could react quickly to the unique needs of ICON, design and custom-make a prototype using local research and development for Australiaspecific conditions, and take it to the manufacturing stage in a really short time, all with the support of Australian workers,” Persson said.
FASTENER UPDATE
FASTENER UPDATE AATP sells commodity threaded rod business to focus on specialty products
• THREADED ROD • STUDS
All America Threaded Products, Inc. (AATP) announced • ANCHOR BOLTS that it has sold its commodity threaded rod business to Vulcan Threaded Products, Inc., as part of a change in its • U-BOLTS business focus. • DOUBLE-END STUDS A press release said that the sale to Vulcan Threaded Products, a division of Steel Dynamics, Inc., will enable • SINGLE-END STUDS ATTP to focus on specialty threaded products at its plants • SPECIALS in Lancaster, Pennsylvania, and Denver, Colorado. “The sale of our large volume low-carbon commodA range of threaded products from AATP. ity threaded rod business allows our team to focus on developing our line of specialty threaded products,” said The roots of AATP were formed in 1994 when parent Casey Broderick, president of AATP. “We are committed company Acme Manufacturing of Denver, Colorado, to our quest of providing an excellent buying experience acquired BoltMaster, Inc. (RediBolt) of Chicago, Illinois. with high-quality threaded products and flexible solutions All America Threaded Products In the following years, Acme Manufacturing made ... a prime U.S. manufacturer of a wide range of quality threaded products. adapted to meet customer needs.” several more acquisitions of threaded products compaAATP domestically manufactures made-to-order threadTO ORDER CALL ROCKY MOUNTAIN MIDWEST MID-ATLANTIC nies, including: Threaded Rod Company, Indianapolis, DIVISION DIVISION DIVISION ed products and tailors their business to create an efficient 1-800-354-3330 www.aatprod.com DENVER, CO INDIANAPOLIS, IN LANCASTER, PA Indiana; Watson Metal Products, Kenilworth, New Jersey; buying experience for customers with quick quote and Lancaster Threaded Products, Lancaster, Pennsylvania; order turnaround, custom manufacturing capabilities, a Rods Indiana, Butler, Indiana; and J&D Industrial variety of stocking options and custom packaging. With Products, Butler, Indiana. Upon completing the acquithe sale of the commodity business, the company is consition process in June of 2010, Acme Manufacturing centrated on maintaining and growing sales with customformed All America Threaded Products and consolidated ers that purchase studs, anchor bolts, U-bolts and specials, all operations into three facilities. while continuing to supply plain and plated low-carbon threaded rod in small quantities.
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WAI
NEWS
WAI NEWS
MEET YOUR PEERS. ACHIEVE YOUR GOALS. JOIN WAI TODAY.
The following individuals either recently joined WAI or became Platinum Members through their companies. Bill Barrett Vice President Sales & Marketing Nexans Energy USA Inc.
Ajoy Gupta Senior Vice President Business Development Aradhya Steel Pvt. Ltd.
Patrick Berube Operation & Technical Manager Hobart Filler Metals
Asjed A. Jalil Business Head Pradman
Derrick Brown Vice President Sales & Marketing Nexans Energy Guilherme Brum General Manager Traxit North America LLC Tae Chang Taihan-Fiberoptic Martin Javier Dalmau CEO Conelsa Lavon Detweiler CEO Entech Inc. Aida Escorza PKC Group
Morten Jespersen Area Sales Manager Roblon A/S Kim Jinho Researcher Kiswire R&D Center Jeonghun Kim Student Jun Young Lee Taihan-Fiberoptic Phichet Lochanachit Technical Director Phelps Dodge International (Thailand) Ltd. Stevan Mehandzic Mika Drive & Automation Services Inc. Clayton Morris Technical Sales Rep Elgin Fastner Group
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Michael Ormsby Wire Drawing Engineer SDI LaFarga LLC Chi Hwan Ouh Taihan-Fiberoptic David Anthony Patterson Department Manager Southwire Co. Mel E. Pearson Key Account Manager DuPont Isham Picillo Process Engineer Marmon Utility LLC Vladimir Rajkovic President Mika Drive & Automation Services Inc. Jose Rivas PKC Group Yvan Rodrigue ArcelorMittal Steven Roe Electron Beam Technologies, Inc. Jung Sang Wook Hyosung Vietnam
Atul Shah Business Development Director Aradhya Steel Pvt. Ltd. David B. Skaggs Technical Sales & Applications Engineering Bechem Lubrication Technology, LLC Yoon-suk Sull Taihan-Fiberoptic Bogoljub Takic Mika Drive & Automation Services Inc. Chris W. Truett Department Manager Southwire Co. Stephane Veillette Executive Vice-President INTRAL Inc. Jose Luis Villanueva Process Engineer Chief Viakable Chanin Yensudchai CEO Phelps Dodge International (Thailand) Ltd.
WAI’s Finance Committee held a meeting on Aug. 30 at its headquarters in Madison, Connecticut, where members—many of whom took part via a conference call—got the latest update from staff.
Companies seeking a display ad in the 2018 Wire Journal International (WJI) Reference Guide must get their order in by Thursday, Nov. 30. Companies whose orders are received by Thursday, Nov. 8, can get a 5% early-bird discount. The Reference Guide includes six sections: company profiles, including contact info and primary products; companies by business types, with 25 different categories; a geographical index, one state-by-state, and one country-by-country; WAI information; a list of WAI members and an ad index. The Reference Guide, which lists thousands of companies, is sent free to WAI members and is available for purchase for $140. For details about placing an ad, contact sales@wai.org.
Committee members Don Schollin and Tom Siedlarz, in back, with WAI’s Dave LaValley and Steve Fetteroll. Don Schollin and Tom Siedlarz were at the office, where WAI Treasurer Dave LaValley updated members on the budget and various initiatives. Topics ranged from results for Interwire 2017 to investments in different technology. Four such meetings are held each year.
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OCTOBER 2017 | 39
WAI NEWS
Ad deadline set for companies that wish to be in 2018 Reference Guide The Wire Journal International 2018 Reference Guide ◆ Published for The Wire Association International, Inc.
WAI Finance Committee meeting had a range of Association matters to hear
Food for thought:
It’s such a favorite, we’re taking reservations for 2018.
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Let all of them know what you bring to the table in this annual buyer’s guide. If you sell wire, cable, manufacturing supplies, or equipment, you’re in. Company profiles are complimentary.
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Here’s a way to let your brand do the talking all year long. Reserve a display ad in the 2018 WJI Reference Guide and we’ll serve your marketing message to your customers. To prospectsturned-customers. And to the entire Wire Association network.
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 16: Lubrication in Ferrous Wiredrawing SUMMARY: This chapter, 15 pages, discusses the below subjects and more. It includes a half-dozen figures and charts as well as references.
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Types of topics covered: • Importance of Lubrication; Impact/ Mechanisms of Lubrication • Wet and Dry Lubes. Available at www.wirenet.org through the WAI Store.
OCTOBER 2017 | 41
CHAPTER CORNER
CHAPTER CORNER 3-way tie and record field define the Southeast Chapter’s Vannais outing The Southeast Chapter hosted its 16th annual golf tournament, The Vannais, on Sept. 21, setting a record for the largest-ever field of players. A total of 127 golfers played at the beautiful and challenging Trent Jones Course at Rock Barn Golf and Spa in Conover, North Carolina. The weather was ideal from start to finish, with blue skies throughout. The awards ceremony and extensive raffle were concluded as participants got to enjoy a picture-perfect sunset over the lush fairways.
Perdue also thanked chapter Vice President Lamar Austin for his efforts in organizing the event, and to all the golfers for their generosity in helping raise funds for the chapter’s scholarship fund. A key to that, he noted, are all the event sponsors who continue to support the good cause. Premium sponsors included: Bekaert, Breen Color Concentrates, Carris Reels, Commission Brokers, Henderson Sales & Service, Houghton International Inc., Flouropolymer Resources, W. Gillies Technologies, Graham Engineering/ American Kuhne, Joe Tools, Lloyd & Bouvier, J. J. Lowe, Maillefer Extrusion, The MGS Group, NDC Technologies/Beta LaserMike, The Okonite Company, RichardsApex, Rosendahl Nextrom USA, Standridge Color Corp., Sikora, Sonoco, Southwire Company, 360 Control Technologies, Technical Development Corp., Teknikor, Wire & Plastic Machinery and Zumbach. Corporate hole sponsors included: Axjo America, Breen
By a card match of the three teams that scored a 59, the winners, l-r, were Cody Lail, Trey Broome, Marcus Kirby and Brian Deese, all of CommScope. “Through the great work by the Board of Directors, all of the outing elements came together, including completing the round in less than five hours,” said Chapter President Jim Perdue, Southwire. “This was the first tournament without Past President Art Deming, who chaired the outing since Steve Vannais passed away in 2011. I am grateful to the Board, all of whom stepped up in a big way to make this happen.” The best ball scramble tournament ended with a threeway tie with scores of 59 and by matching score cards, the winners were declared to be the CommScope team of Cody Lail, Trey Broome, Marcus Kirby, and Brian Deese. The second place team was Tim Moore, Zumbach; Brian Johnson, CommScope; Gene Mallacoccio, Petco Sackner; and Brad Chapman, Corning. The third place team, Standard Tytape Co., included Mark Burns, Bob Hermann, John Smith and Toby Golloway. “This year’s event was another great Vannais outing, hats off to the organizers for a job very well done!” said Eric Kalis of Breen Color Concentrates. He added that, from a business standpoint, he was quite pleased to hear of the CommScope team victory as “the CommScopeBreen Color partnership is a proven winner!”
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Southeast Chapter Board members, l-r, at the dinner: Tim McElhany, Jim Perdue, Chris McGill, Woody, Holland, Orlando Martinez, Mike Sears and Brooke Stonesifer. Not shown: John Dognazzi, Lamar Austin and Bryan Sullivan.
Color Concentrates, Clinton Instrument, Davis-Standard, Davis-Standard Aftermarket, Fluoropolymer Resources, Gateway Recovery, Gem Gravure, Haynes Wire Company, J. J. Lowe, Joe Tools, Keir Manufacturing, LS Cable & System, Magnum Manufacturing, National Drayage Service, Process Control Corp., QMS America, Sonoco Plastics, Sonoco Reels, Southwire Company, T&T Marketing, Teknikor, Wayne Wire Die, Windak and Wire & Plastic Machinery.
Sept. 12 was a simply glorious day for the New England Chapter’s 23rd Annual Golf Tournament, which set a new high for attendance, with more than 180 registered golfers, as well as a record for fundraising for the chapter’s annual scholarship program.
join the best: 16 – 20 April 2018 Düsseldorf, Germany www.wire.de
The winning team of Ken Berube, Greg Gitto, Ron Reed, and Scott Reed, with John Rivers, l, and Derek Olson 3rd from l. “What a great showing of support for our scholarship fund from the NE Chapter. I am so glad Mother Nature was also so supportive by giving us such a beautiful late summer day,” declared chapter President Derek Olson, Gem Gravure. “The outdoor patio setup gave a great view of the Farmington River Valley and another chance to connect with colleagues before the dinner and raffle all the while enjoying a perfect late summer New England day. There was a lot of busting chops out on the course, but it’s all in good fun, and at the end of the day, they proved to be golfers with hearts.” Players indeed were very generous, with many teams opting to pay a $20 donation at a designated hole for one player to take a second tee shot. Between those donations and the raffle, always a buzz of activity, more than $4,000 was raised for the scholarship fund. Altruism aside, the goal was to win, and Ron Reed, Lloyd & Bouvier, Scott Reed, Horizon Wire and Cable,
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Recalling the day’s ups and downs is utterly essential.
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For show information: Messe Düsseldorf North America 150 North Michigan Avenue Suite 2920 _ Chicago, IL 60601 Tel. (312) 781-5180 _ Fax (312) 781-5188 info@mdna.com _ www.mdna.com For hotel and travel arrangements: TTI Travel, Inc. Tel. (866) 674-3476 _ Fax (212) 674-3477
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OCTOBER 2017 | 43
24.08.17 10:32
CHAPTER CORNER
New England Chapter tourney sets records for attendance and fund-raising
CHAPTER CORNER
CHAPTER CORNER
A pleasant day, well-groomed greens, course refreshments and camaraderie: what more could a golfer want? Greg Gitto, Color Resource LLC, and Ken Berube, RSCC, retired, shot a crisp 61 to win. “Scott and Greg hit the ball a long way, so on most holes it was an easier second shot into the green where we all putted well. The key was no boggies,” Ron Reed said. Coming in second, at 62, was the Southwire team of Todd Chikodroff, Chris McGill and Jim Perdue. Third place went to Bob Canny, TE Wire & Cable; Bob Smith, Fluorogistx; Joe Barry, Comtran Cable; and John Netta, Chemours. Premium sponsors included: Accel International, Amacoil, AGC Chemicals, Arkema Inc., Breen Color, Carris Reels, Cable Components Group, Chase/NEPTCO, Clinton Instruments, Colorant Chromatics, Commission Brokers, DeWal Industries, Inc., EIS Wire & Cable, Electric Cable Compounds, Fenton Group, Inc., Fisk Alloy, Fluorogistx, Fluoropolymer Resources, GEM Gravure Co. Inc., James Monroe Wire & Cable Corp., Joe Snee Associates, Joe Tools, Leoni Wire Inc., Mantec, Marmon, Mexichem, Millard Wire & Specialty Strip, Multi/Cable Corporation, NDC Technologies, Omni Source, LLC, Plasticolor, Process Control Corporation, Quabbin Wire & Cable, Quirk Wire Co., RichardsApex,
The outdoor buffet layout was a big hit.
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RSCC, Sikora, Summit Corporation of America, Specialty Cable Corp., Summit Corporation of America, T&T Marketing, Teknikor Contracting, Teknor Apex, Times Microwave, W. Gillies Technologies, Whitmor/WIREnetics, Wire & Cable Manufacturers’Alliance and Wire & Plastic Machinery. Corporate Hole sponsors included: Derek Olson parred the master of Accel International, ceremonies duties. Amacoil, Arkema Inc, Carris Reels, Cable Components Group, Clinton Instruments, Colorant Chromatics (2), DeWal Industries, Inc. (2), EIS Wire & Cable (2), Electric Cable Compounds, Fenton Group,
Despite record attendance, accommodations were superb for both the course and the dinner/raffle.
Inc., Fisk Alloy, Fluoropolymer Resources, Gem Gravure, JMWCC (4), Joe Tools, Leoni Wire Inc., Mantec, Millard Wire & Specialty Strip, NDC Technologies, Plasticolor, Process Control Corporation, Quabbin Wire & Cable, Quirk Wire Co., RichardsApex, RSCC, Summit Corporation of America, Specialty Cable Corp, T&T Marketing, Teknikor Contracting, Teknor Apex, Whitmor/ WIREnetics, Wire & Cable Manufacturers’Alliance and Wire & Plastic Machinery. “Thank you to all our sponsors, volunteers and participants,” Olson said. “We hope to see you next year to once again benefit this great cause.” He also thanked the chapter volunteers, led by John Rivers, Fluorogistics.
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The Wire Association International, Inc. Telephone: (001) 203-453-2777 | www.wirenet.org
If this first-time feature looks familiar, you’d be right. WAI’s Board of Directors believes that there are a lot of talented professionals in the wire and cable industry, and that highlighting some of the younger people in a wire and cable industry version of a “30 under 30” series would be most fitting. The age range was extended some, and the goal for this initial effort was to include a dozen or so staffers. Requests for nominations were sent out, and the results are noteworthy. The field ranges from one person with less than two years of experience and a staffer who manages international sales activities and has coauthored 10 technical papers to the founder of an IoT company that has shown incredible growth in a very short time and a longtime General Motors staffer who now heads maintenance in North America. What they all have in common is that they are well respected in their fields, and are the kind of people who by their work ethic and effort set a good example for their colleagues in the wire and cable industry.
ck lf or volleyball, Patri When not playing go ed lov be his ng for Morrisey enjoys rooti x. So d Boston Re
Tromp i wife, ng the grea Alexis , and t outdoors: son, M C ycroft ody Davis . ,
The value (or cost) of a workforce • Employee productivity grew .3% a year over the last five years, from 2011 to 2016. (Source: BMC Public Health) • Productivity improves by 20-25% in organizations with connected employees. (Source: The McKinsey Global Institute)
• A business with 100 employees spends an average downtime of 17 hours a week clarifying communication,
46 | WIRE JOURNAL INTERNATIONAL
translating to an annual cost of $528,443. (Source: Siemens) • Disengaged workers had 37% higher absenteeism, 49% more accidents, and 60% more errors and defects. (Source: Queens School of Business)
• Employees who feel their voice is heard at work are 4.6 times more likely to feel empowered to perform their best work. (Source: Salesforce.com)
His fast track success has already helped garner awards Cody Davis, 30, is an advanced product engineer for utility products for General Cable Corporation (GCC). He provides technical customer support for west coast customers and leads overhead conductor projects. He was a key driver for GCC’s award-winning E3X® Technology, and was a contributor to 10 company patents. He holds a B.S. degree in electrical engineering and a master’s degree in electrical and computer engineering, both from the Rose-Hulman Institute of Technology. He joined GCC in 2009, and is active in IEEE, chairing a working group and two task force bodies. He also is the company’s representative for the Aluminum Association. Per the company nomination, “Cody’s been on an accelerated development path with our Utility Engineering Team. After learning wire and cable fundamentals, developing systems and an advanced knowledge of the business, he now leads project activities for overhead conductors and provides customers tech support in the west region for all utility products. He also mentors training program engineers and co-ops and serves in key volunteer roles for multiple industry organizations. He consistently exceeds our expectations. His passion, creativity and dedication were instrumental to our E3X® Technology winning the prestigious Gold Edison Award. He aspires to be extraordinary, and in doing so makes General Cable a better place.”
Cody Davis Advanced Product Engineer General Cable Corporation Years Experience: 8 College: Rose-Hulman Institute of Technology
Very new, very young, yet already making a difference Patrick Morrisey, 23, is a quality analytical engineer for Mexichem Specialty Compounds at its plant in Leominster, Massachusetts, which supplies a range of compounds. He holds a B.S. degree in plastics engineering from the University of Massachusetts-Lowell. While at school, he worked two summers (2014-15) as an intern in Mexichem’s R&D department. He was hired in late 2016, and with a little over a year of service is now part of a lab team dedicated to ensuring product quality. He interacts with customers on compound use, and goes to their plants to help troubleshoot any cable processing issues. Per the company nomination, “Patrick has displayed an incredible level of patience and creative thinking. His communication skills have been effective and he has worked well with the older and more seasoned veterans of the business. He has made strong contributions to standardizing our testing procedures, and he is very good at helping customers. He always seems to ask the right questions, leading to the right recommendations. His mature demeanor is very impressive. I took him to a customer for a second trial when we had to modify a formula. As Patrick was so new, I wasn’t sure what he could contribute, but he came up with new conditions and improved the product. He won over two seasoned veterans and a long-time molder.”
Patrick Morrisey Quality Analytical Engineer Mexichem Specialty Compounds Years Experience: 1+ College: University of Massachusetts-Lowell
OCTOBER 2017 | 47
Sowing a digital path to advance wire and cable production Willem Sundblad, 29, is the co-founder and CEO of Oden Technologies, a U.S. industrial IoT company that provides a data acquisition and analytics platform. He works closely with wire and cable manufacturers to show them how the Oden platform and Industry 4.0 technology can enable their factories to digitize production, eliminate waste and continuously improve by using clear data and actionable insights from their equipment. He holds a degree in industrial engineering and management from The Faculty of Engineering in Lund. He has seen first-hand how many production constraints faced by manufacturers could easily be solved, and since then, his mission has been to develop technology that enables factories to achieve their optimum production.
Willem Sundblad CEO & Co-founder Oden Technologies Years Experience: 6 College: Lund University, Ecole centrale de Paris
Per a nomination from a business associate, “The first time I met Willem was at wire Düsseldorf 2016, where he introduced me to his new start-up company. He had big ideas for introducing the Smart Factory to the cable industry and a year later I was impressed by how considerably his company had grown. Oden Technologies showcased a fine set of data capture and analysis tools at Interwire 2017, during which he was also part of a panel discussion on Industry 4.0. To achieve the level of success he has in such a short time, in a very traditional field, demonstrates Willem’s understanding of the industry, his belief in the technology and a great deal of determination.”
ns, ountai s m e h t e enjoy rives in blad th the season, h d n u S Willem epending on . g d where ing and skiin k i h both
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Nicolas Rosa understands the slippery slope th eory ... he d oesn’t lose his cool when things start going downhill.
A quick learner with an instinct for finding opportunities Nicolas Rosa, 27, is the engineering & product development supervisor for Cable Components Group (CCG), at its plant in Connecticut. He joined CCG in 2012 as a product engineer and was promoted in 2017. He is responsible for spearheading key developmental projects at CCG, which manufactures extruded cabling profiles and compounds for cable fillers, insulations, jackets and fiber optic tubing. He holds a B.S. degree in mechanical engineering from the University of Virginia, and is working on an MBA at Indiana University. At IWCS 2016, he made a New Product Presentation. He works closely with customers and supervises a team of engineers to drive innovation, achieve company milestones and help customers win business. Per the company nomination, “Nick is a strong, assertive engineer who approaches each project with enthusiasm and passion for success. He possesses strong leadership and interpersonal skills to motivate and drive others toward success. He identifies and aggressively troubleshoots new opportunities for CCG, taking them from the initial stage through completion. Nick has grown immensely in his five years here, he has become a strategic contributor with his entrepreneurial decision-making skills. He is listed as an inventor on two company patent applications. He is well-respected by both his colleagues and CCG’s customers, and he truly exemplifies a team player. Nick is an asset to our firm and to the wire and cable industry.”
Nicolas Rosa Engineering & Product Development Supervisor Cable Components Group Years Experience: 5 College: University of Virginia
OCTOBER 2017 | 49
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A tech wonder who knows how to create and share Wade P. Krejdovsky, 40, manages sales activities with ferrous long rolling customers in Europe and Near East for Primetals Technologies USA LLC, a designer and manufacturer of high-speed rod mills. Based in Worcester, Massachusetts, he oversees everything from mill audits and sales proposal specs to project tracking and final commissioning. He worked for Precision Castparts for five years and in 2005 joined the former Morgan Construction Company operations that were subsequently bought by Siemens, which in turn was bought by his current employer in 2015. He has coauthored 10 technical papers, one of which won a WAI Silver Certificate Award in 2016, and holds a B.S. degree in materials science and engineering from Lehigh University, and an MBA in management from St. Joseph’s University.
Wade P. Krejdovsky Sales Manager, Sr. Rolling Technology Advisor Primetals Technologies USA Years company experience: 18 College: Lehigh University/ St. Joseph’s University
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Per the company nomination, “Wade brings the wonderful combination of a collaborative nature and technical expertise. He works well with colleagues in different departments and disciplines and has the technical expertise to identify appropriate solutions for customer problems. He has shared his knowledge at technical conferences around the world. He was one of the three people who launched the Global Ferrous Rod & Wire Symposium that was co-located with Interwire 2017, an effort led by Gerdau’s Bhaskar Yalamanchili, with help from Wade and colleague Bruce Kiefer.”
A quick study with the confidence to be a leader Alejandro Solis, 25, is a quality and project coordinator for Viakable at its plant in Monterrey, Mexico. Fluent in German and English, he previously worked for Mahle twice. The first time was as a preventive quality intern in Germany in 2013—made possible by his winning a Baden-Württemberg scholarship—and the following year, as a quality engineer in Mexico. In between, he also was a quality systems intern for John Deere. He joined Viakable in 2016 as a quality engineer. He holds a B.S. degree in mechanical engineering with a minor in administration from the Monterrey Institute of Technology, and is currently pursuing a master’s degree in quality systems and productivity with a certification in Six Sigma Black Belt. Per the company nomination, “Alejandro has proven to be a key team member. His leadership, dedication and perseverance has been a key factor in our accomplishing company goals and objectives. By implementing projects related to Industry 4.0, he has been able to increase process efficiency, reduce scrap rate and lower fabrication cost on several process lines. Alejandro is responsible for new product application development and plant quality, and is now leading a significant fiber optic cable plant project that is quite demanding. In his short time here, he has shown himself to be a quick learner, an important company asset and a treasured staff member. Alejandro is rising to greatness.”
Alejandro Solis Quality/Project Coordinator Viakable Years company experience: 1+ College: Monterrey Institute of Technology
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Where are all the good employees...and how do you keep them? Industry, fortunately, is more than just equipment and orders, and the quality of staff has been called by some industry veterans as the biggest differentiator. Below, Peter Carino, the principal of Wire Resources, Inc., who has 35 years of experience in wire and cable recruiting, shares his thoughts. WJI: How hard is it for you to find young professionals with two or three years of wire and cable experience? Carino: Non-technically degreed, young professionals are scarce in the cable industry. Degreed engineers with two or three years of wire and cable experience are like hen’s teeth. It’s common for a cable manufacturer to have not one technically degreed engineer with a couple of years of experience. I don’t believe it’s any more difficult to hire young professionals today, but it’s undeniable that today’s young people move from job to job at a greater rate than a generation ago. They are more often renters of housing, not buyers, and marry at a later age and are less tied down. WJI: Are companies more willing to hire someone just out of college? Do internship programs matter? Carino: Larger cable producers are more likely to hire young grads. You see it occasionally at smaller cable firms, but those companies may not have the luxury of investing the time and training needed to get those young employees to a point where they are contributing to the bottom line. If a recent grad has an internship at a cable company, it would certainly be an attraction. The experience—and more importantly, the interest in a possible career in the cable industry—is a plus. WJI: In real estate, the mantra is “Location, location, location.” Does that apply to wire and cable too? Carino: To some extent. If a cable plant is in a very rural location, it will appeal to a smaller pool of potential candidates. If it’s in an area with all of the amenities it will appeal to a larger group. However, if the cost of living is too high, the candidate pool again becomes small. A person getting started or an employee with a family both want to live in an area that offers the lifestyle they seek, with proximity to what’s important to them, e.g., schools, social life and facilities. The dynamic of work versus personal life is more intertwined than ever. WJI: When companies come to you to seek a candidate, can their requests be unrealistic? Carino: Occasionally, and if so I’ll tell them why, giving specific examples. Requests can be unrealistic for a
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variety of reasons. Typically, it’s base compensation, incentive, relocation assistance or an unusual skill set they seek. However, there are other factors, like Peter Carino historical company turn over, industry reputation and location that potential candidates, will take into consideration when determining what the company has to “offer.” WJI: The wire and cable industry tends to be overshadowed by other glitzier fields, yet you have said more than once that it often has more potential: what do you mean by that? Carino: When I speak with a young person working in the cable business, I encourage them not to leave. I tell them that there is more potential and opportunity to grow in their field as there is less competition from similar age peers. The cable business was run “lean” long before it became fashionable and therefore the young hire, who is one of few, will be exposed to more things and at a faster rate. A deeper, more well-rounded experience in a shorter period of time is probable. One can leverage that experience for accelerated career growth. WJI: Is it harder for a company to hire a young staffer? Carino: I believe it’s harder to hire the young grad, especially if it’s an engineer. A career in wire and cable manufacturing is not on the radar of most new grads. Secondly, you have to pay market value. Other industries tend to pay equal or greater wages than the cable industry. You compete with other industries for the educational background, perceived potential and the candidate’s “soft skills” you feel they possess. WJI: When people come to you looking for a new job, is the goal inevitably to get a bigger paycheck? Carino: Current compensation typically is not the primary motivator when a gainfully employed person calls me looking for a new job. Obviously, money is important but that’s not the first thing I usually hear. The company direction and how that message is conveyed to its employees is a big factor. Does the company operate with a short term view or does it have a reputation and strategy
for long-term growth? Maybe the path for advancement is no longer available for the plant manager who wants that vice president of manufacturing position, but his boss has been with the company 15 years and “isn’t going anywhere.” A caustic relationship with the boss, regardless of who is at fault, is always a motivator for job change.
the plant floor on up, it usually bodes well for company morale. I have walked through dozens of wire and cable plants with the plant manager or a senior executive. You can usually tell what type of relationship exists between the plant floor and management by listening and seeing their casual interactions.
WJI: What can a company do to maintain key staffers? Carino: No one gets a more honest exit interview than someone in my position. Employees don’t want to burn a bridge when they leave a company. When HR asks them what prompted their move, they will give a generic, fairly benign response: better opportunity, more money, closer to home. Those reasons are probably true but typically there is an underlying factor that won’t be stated. Employees want to feel like they are truly a part of the team. They want a clear message and strategy even though they understand that priorities can and will change. They want their input recognized and at least considered. Some companies openly display goals and milestones that detail company performance. Employees like to know where they stand, and more importantly, how their actions affect those goals, and ultimately, their total compensation. Knowing your employees on a personal level can be very helpful. When a senior executive puts in the time to talk and listen to employees from
WJI: What was not asked above that you feel is worth noting? Carino: There are certain cable manufacturers that have a history of low turnover, which typically equates to employees taking greater ownership of their responsibilities and going the extra mile more often. You want your employees to work like they own the company. That’s the reason ESOPs have very little turnover. An ESOP employee is likely to have an entrepreneur’s work ethic and vision, which is tough for the competition to beat. There is a small ESOP cable manufacturer that has never had an unprofitable year or an employee leave their company to join another firm. Every past employee either retired from the company or passed away. That performance and level of commitment is tough to dispute! Peter Carino, Wire Resources, Inc., can be contacted at tel. 203-622-3000, pcarino@wireresources.com or at linkedin.com/in/petercarino1
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A smart tech guy who focuses on real-world results John Dudus, 34, is sales engineer for The MGS Group, (MGS Manufacturing, Hall Industries & Northampton Machinery) based in Rome, New York, an OEM manufacturer of wire and cable processing and packaging equipment that also supplies bunching equipment from its U.K. operation, Northampton Machinery, Co. He has significant interaction with customers, both domestic and international, for sales of new machinery. He joined The MGS Group in 2013, and was previously a mechanical engineer and sales engineer for Bartell Machinery, where he worked from 2005 to 2013. He holds a degree in mechanical engineering from Clarkson University.
John Dudus Sales Engineer MGS Group Years company experience: 4 College: Clarkson University
Per the company nomination, “John stands out in a quiet way: he is blessed with creative engineering skills and a way of making customers feel very comfortable. He is determined to find a way to make things work for customers and the process is more like a partnership. For instance, one company had very specific requirements for a wire take-up to increase productivity. John, working with our R&D staff, came up with an alternative. He explained how for the given application, an accumulator would provide both better overall production and greater ROI. The customer agreed to go that route, and has been thrilled with the results. Yes, there are concerns today that there is a lack of technical knowledge in the field, but we feel that as long as there are people like John in the industry, its future is secure.”
Armed with a PhD and the tools to find a better way Michael Kahl, 30, is an analytical chemist at the R&D Department at Encore Wire Corporation in McKinney, Texas. He joined the company in 2016 after completing a Ph.D. in analytical chemistry from the University of North Texas. He previously worked at a semiconductor materials company and a pharmaceuticals testing laboratory. His responsibilities include environmental testing, raw materials screening, process monitoring, and plastics analysis. He oversees and maintains a lab that has more than a million dollars’ worth of analytical equipment. He is training to become Encore’s resident expert in flexible PVC formulation and extrusion.
Michael Kahl Analytical Chemist Encore Wire Corporation Years company experience: 1+ College: University of North Texas
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Per the company nomination, “Michael combines great technical expertise with the ability to learn on the fly. He has become familiar with various testing standards (UL, ASTM, EPA), plant processes, cable construction and plastics formulation in a short period of time. He communicates effectively at all organization levels and welcomes projects outside of his comfort zone. At Interwire 2017, he presented a technical paper, Increasing Building Wire Voltage Ratings from 600 V to 1,000. He collaborates internally with production, engineering, and codes and standards as well as externally with suppliers for recycling of copper from wire and cable waste streams. In a very short time, he has become an important company contributor.”
Staffer was ‘well-grounded’ before she entered industry Stacy Martin, 39, is the maintenance manager at General Cable Corporation’s manufacturing plant in Marshall, Texas. She is responsible for development, coaching, and mentoring 37 skilled hourly and six salaried team members. She was an electrician for five years, including a period during which she also attended Louisiana Tech University, where she earned her degree in electrical engineering and an MBA. She worked for General Motors for 16 years, winning the Society of Automotive Engineers Young Leadership Award in 2011. In 2012 she joined General Cable Corporation as a senior process engineer. She served as a value stream manager from 2013 to 2015, at which time she became the Marshall plant maintenance manager. Per the company nomination, “Stacy is a rising star in our organization. She is smart, driven, and a natural leader. Stacy is also very flexible as she has excelled in engineering roles, manufacturing management roles, as well as maintenance. In her current role, she leads a large maintenance organization in General Cable’s largest North American facility. As is typical of any large facility, the hours are long and the pressure is high. Stacy manages both with ease as she stays focused on reducing unplanned down time, which she has cut by 40% in the last two years. In summary, Stacy is a proven winner!”
Stacy Martin Maintenance Manager General Cable Corporation Years industry experience: 5 College: Louisiana Tech University
ring new sizzles at maste les, a Thai Michael Kahl spicy basil nood cook. recipes, such as ught nges the self-ta dish that challe
John Dud us ing Oneid cruisa Lake in upstate N ew York in search of the chill life.
In addition to travel, Stacy Martin enjo ys powerboating with her family.
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A millennial with an old-time sense of responsibility Jose Pineda, 30, is the human resources/safety manager of Insteel Industries’ 48-person PC strand manufacturing facility in Houston, Texas. He currently is attending LoneStar College. He joined the company in 2014, and is responsible for guiding all facets of the company’s human resources strategy and ZERO HARM safety strategy. He heads efforts for creating HR strategy, assisting with development and implementation of policies and procedures and leading organization change efforts.
Jose Pineda HR/Safety Manager Insteel Industries Years company experience: 3 College: LoneStar College
Per the company nomination, “Someone forgot to tell Jose how people expect millennials to act. There is no sense of entitlement, no lack of initiative, no expectation of gratitude for simply showing up and no reluctance to do what is needed. Jose began as an hourly associate but potential for leadership was evident early on. During the aftermath of Hurricane Harvey, Jose didn’t hesitate to go out into the waist high water to help evacuate people from their neighborhoods. When you discuss his successful performance, Jose’s response is humble appreciation followed by immediate recognition of his general manager’s guidance. He is a strong example of a young professional doing an incredible job of ensuring the company’s continued success.”
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Work is a te am and that goes experience for Jose Pin eda for his off-du Above, the “ ty passion: so , Real Unicorn ccer. ” and his mate s celebrate a middle defender championsh ip win.
An industry maestro at improving processes David Killmeyer, 28, is a manufacturing engineer at Rochester Wire and Cable LLC, a TE Connectivity (TE) company in Culpeper, Virginia. He joined the company in 2013, and is responsible for several process improvement projects in the wire drawing and armoring departments at TE, which manufactures harsh environment electro-optical cables. He holds a B.S. degree in mechanical engineering from Penn State University, and recently became an ASQ Certified Six Sigma Green Belt.
David Killmeyer Manufacturing Engineer Rochester Wire and Cable LLC Years company experience: 4 College: Penn State University
Per the company nomination, “David is a self-motivated and outstanding process engineer. He is well respected by operators and management alike, known to get tasks done quickly and effectively. His efforts in the wire mill can be seen in all aspects, from parameter setup sheets to visual data capture boards. Last year, he flawlessly orchestrated the installation of a new 14-block wiredrawing machine. He has also led several Kaizen events that lead to reductions in cost and increased workflow. He also happens to be the plant’s Quick Change-Over tool champion. He has quickly expanded his knowledge of wire and cable and has a bright future in the business. That’s why we gladly sent him to sit in on the Fundamentals of Wire Manufacturing course at Interwire 2017, as it was another step that further strengthens his ability to support the wire drawing department.”
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In control, whenever and wherever it is necessary David Mancini, 34, is an application controls engineer at Nexans Canada, Inc. He has been there for five years, previously working for six years in the automotive field as an automation technician, control engineer then plant engineer. He holds a degree in engineering systems and computing from the University of Guelph. A licensed professional engineer and industrial electrician, his responsibilities range from working on new production lines and developing standardization of control systems to implementing new process and control methods and updating existing mature systems throughout the plant.
David Mancini Application Controls Engineer Nexans Canada Inc Years company experience: 11 College: University of Guelph
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Per the company nomination, “David entered our group, and immediately contributed and has continued to do so. He has developed new application software to reduce materials consumption that can be used for all product types and is transferable to any control system. He designed a new control system that reduces scrap by developing an equation that analyzes product in real time and adjusts as necessary to get the most of the machine, both mechanically and electrically. He is very methodical. He assesses each aspect, analyzes an entire system/problem, researches and ultimately proposes a long-term solution that he then implements. Beyond that, as machines became more complicated electrically, the skills to troubleshoot and support the processes has become more important, and David has excelled there too. He is our all-around ‘go-to’ guy.”
Furthering a family legacy in a challenging field Jarrett Martin, 38, is vice president of MAR-MAC INC, a family-owned steel wire producer in McBee, South Carolina. He joined the company in 2009, and served as director of sales and marketing before his promotion to vice president in 2016. He served from 2003 to 2007 as a legislative advisor to the office of the governor of South Carolina. He holds a degree in economics from SewaneeThe University of the South, and an MBA degree from the Darden Graduate School of Business Administration from the University of Virginia. Per the company nomination, “Jarrett continues the family tradition at MAR-MAC Inc., where he started out as a wiredrawer over college summer breaks. He took two years off to complete his MBA degree and then joined his uncle, father and brother as a customer service representative in 2009. He has since spent time learning all business facets, from sales and customer service to accounting and maintenance and engineering. He has displayed a keen ability to communicate clearly and to make complex and complicated concepts understandable. He is on track to take over the company when his dad retires, a heady responsibility, and while he will be keenly challenged by foreign competition as well as larger and well-funded domestic rivals, we are excited by his ability to handle the challenges to come, and the role his faith will play.�
Jarrett Martin Vice President MAR-MAC INC Years company experience: 8 College: University of Virginia
Innovation meets Tradition
THE buttwelding company since 1933!
Oct. 03-05, 2017 Sao Paulo, Brazil booth 502
www.strecker-limburg.de www.streckerusa.com
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PRODUCTS TECHNOLOGY Product line provides the quality control that is needed to drawing optical fibers With the company’s FIBER Series 6000, Germany’s Sikora AG notes that it offers complete intelligent measuring and control technologies for online quality control of optical fibers in the drawing tower. A press release said that quality control of optical fibers in the drawing tower starts below the preform with the FIBER LASER 6003 for diameter and position measurement of the uncoated fiber and the evaluation of the fiber tension. A FIBER TEMP 6003 is usually installed at the hot end of the drawing process for measuring the temperature of the optical fiber in order to control the furnace. After the forced cooling, the diameter of the optical fiber is measured once again by a FIBER LASER 6003 or, alternatively, by a FIBER LASER 6003 AIRLINE gauge head, the release said. The latter additionally provides an airline detection. Besides, a temperature measurement is carried out by another FIBER TEMP 6003. At this position, a temperature measuring gauge head is of particular interest for manufacturers of optical fibers as with the information on the fiber temperature, they can use the exact amount of helium that is needed for the cooling and thus save cost. After the optical fiber has received its coating and has gone through the UV drying process, a further FIBER LASER 6003 determines the diameter of the coated optical fiber, the release said. Optionally, a FIBER LASER 6003 CCE, which also gives information on the coating concentricity, can be used as well. In a final step for quality control, the surface of the optical fiber is inspected for any lumps and neckdowns by the FIBER LUMP 6003. For particularly high quality requirements, SIKORA alternatively offers the FIBER LUMP 6003 MICRO with six measuring axes for a 100 % detection/inspection/verification from a fault height of .2 mil (5 μm). The measuring values and information on the surface quality are visualized at the connected processor system 60 | WIRE JOURNAL INTERNATIONAL
FIBER ECOCONTROL and support the manufacturer to take further actions to control and optimize the drawing process. Contact: Sikora AG, sales@sikora.net, www.sikora.net.
Wet drawing equipment redesigned to offer most dry drawing benefits Italy’s Gimax reports that a redesign of its wet drawing equipment and the traditional “submerged” drawing tank has evolved into the “TRS” range of non-slip wet drawing units (pictured) with independently driven vertical capstans. A press release said that the advance combines most of the benefits of a dry drawing line with a wet one for input wire diameters that start at 2.0 mm (steel wire) or 3.00 mm with aluminum wire. The TRS is a “spray” type wet drawbench, where the lubricant is sprayed onto the die and die box and onto the capstan. The range is ideal for both ferrous and nonferrous wires. The model has a reduced footprint, offering easy access to parts and components as well as cost savings in terms of floor space and labor (operation and maintenance) and decreased downtime, the release said. The result is high productivity and a better final wire quality coupled with features such as perfect alignment of wire between die and capstan as well as low-energy consumption due to the latest electronic control of motor and line operation. The TRS line, the release said, results in reduced die and capstan wear; a mechanical line speed up to 33 m/s; use of either fixed or rotating dies; a rotating die speed that varies in proportion to line speed; ability to bypass each block; and synchronization by means of a dancer arm. Gimax notes that with 38 years of experience in welding wire machinery, the redesign also led to the introduction of a range of “TRD” dry drawing equipment, available with vertically or horizontally mounted capstans that are non-slip (with independently driven capstans), tilted horizontal capstans, rotating dies, water-cooled capstans,
Multiple LS HFFR compounds meet new EU fire standards now in effect U.S.-based Teknor Apex Company notes that it offers a full line of cable compound products that meet the European Union’s new Construction Products Regulation (CPR) that recently took effect. A press release said that Teknor Apex Company is prepared to provide wire and cable manufacturers with low smoke halogen-free flame-retardant (LS HFFR) compounds which enable cables to comply with CPR for fire performance. CPR affects products for permanent instal-
lation in a building structure, such as data cables, control cables and building wire. As of July 1, 2017, cable manufacturers supplying such products to European markets must make a ‘Declaration of Performance’ certifying that a particular product meets CPR performance standards as validated in stringent testing by an independent body. As initially promulgated, CPR focuses on the “fire reaction” of a cable: its contribution to fire propagation through heat given off in combustion, the amount and transparency of the smoke emitted, and the acidity of the gases given off. The fire reaction of a cable is indicated by a classification system, with cables ranked from B2ca to Fca. Class B2ca requires the lowest heat release, lowest fire growth rate, and lowest flame spread performance from cable testing.
WIRE MACHINERY KOCH and WIRE always the superior solutions
We supply: Dry drawing machines Single block drawing machines Coilers and Spoolers Reinforcing steel lines Auxiliary machines Project planning
www.koch-ihmert.de www.morgan-koch.com OCTOBER 2017 | 61
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etc. The capstan diameter can vary from 300 mm up to 1200 mm depending on the application and diameter of wire, and can reach a line speed of 35 meters/second. For nonferrous applications (aluminum), the drawbenches are often used in combination with shaving or other equipment. Gimax also manufactures fully automatic and semi-automatic respooling machines and a full range of no-twist after packing units. Contact: Gimax Srl, info@gimaxgroup.com, www.gimaxgroup.com, and in the U.S., Cable Consultants Corp., tel. 914-834-8865, fhardy@ cableconsultantscorp.com, www.cableconsultants.com.
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“Teknor Apex is experienced with CPR classifications and has already helped customers in their programs for achieving CPR compliance,” said David Braun, Teknor Apex wire and cable industry manager. “Among Halguard compounds now available are products suitable for class B2ca and below under the new system.” Contact: Teknor Apex, tel. 401-725-8000, vinyl@teknorapex.com, www.teknorapex.com.
New company in India to offer quality wire and cable to the global markets Isinox Alloys, a new company in India, is offering a wide range of wire products, from flexible coaxial cable and audio/video cable to vehicle signal cable and network cable/data transmission cables and more. A press release said that Isinox Alloys has developed a corrosion-resistant aluminum alloy wire, grade 5154, that achieves maximum tensile strength through a multi-step thermal treatment. The grade, which provides 21-25 kg per mm square tensile strength and elongation of 10%14%, can be used for cable conductors, braiding and shielding and single wire (and other) conductors. Those are typically used for a variety of electronic components, lead wire such as capacitors, resistors, clips, staples, paper clips, and more.
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62 | WIRE JOURNAL INTERNATIONAL Guill Ad5162 “Bullet” WJ 2016
The company is new but is led by industry veterans with decades of experience, the release said. The focus is on manufacturing the finest quality alloy wire available, and to that end the company has a fully equipped automatic die shop having laser, Conoptica and all other die checking equipment to facilitate its wire drawing plant. The full range of grades offered by Isinox Alloys includes 5019, 5050,5052, 5056, 5154, 5356, 5754, 6101, 6202. Delivery time for 100 ton fine wire is 25 days and for larger sizes (size 0.800 to 6.5 for 250 ton) delivery can be made within 30 days. The wire is available in spools from 1 kg to 5 kg. Contact: Isinox Alloys, tel. 91-9811078882, sales@isinoxalloys.in, www.isinoxalloys.in.
U.S.-based Aversion Technologies, Inc., has introduced a combination of non-toxic deterrent chemicals embedded in a wire coating that it said dramatically reduced rat damage in treated wire bundles in a randomized study it had commissioned Texas A&M University to do. A press release said that male rats were even more disgusted by the bittering agents and capsaicin combination in Aversion Technology’s Repela™ plastic additive than female rats. “Wire damage was reduced by almost 80% in the case of male rats during their first exposure to the treated wire coating,” said Dr. Courtney Daigle. “Damage scores were even lower in the second exposure to the treated wire. Animals have memories. How long-lasting
they are, we don’t know, but the male rats in particular seemed to learn that chewing on the treated wires doesn’t taste very good.” The release said that rodents are estimated to cause over $19 billion in economic damage annually in the U.S. Rodents, which include rats, mice, squirrels, pocket gophers, chipmunks and larger mammals such as beavers, porcupines and groundhogs, must continually gnaw on items to wear down their incisor teeth, which never stop growing. Electric and fiber optic cables are particularly attractive to rodents, helping make squirrel damage the #1 cause of power outages in the U.S., according to the American Public Power Association. Rats and mice are especially attracted to so-called “green” vehicle wiring that employs a biodegradable— and apparently delicious—soy-based coating. Gnawed soy-based automobile wiring has become so common, and is so expensive to repair, that it has spawned class-action lawsuits against two automakers—Honda and Toyota— since 2015. Aversion Technologies’ founder Peter Tutini said that Repela does not harm animals. Further, as it is embedded in plastic, it doesn’t leach into the environment. Contact: Aversion Technologies, Inc., www.aversiontech.com.
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Roll-thru payoff and take-up can be configured for multiple applications
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Product allows 1 person to move as many as 18 Cat. 6A cable reels solo U.S.-based Graybar offers a cart that can store up to 18 reels and be moved as needed by a single employee. A press release said that the company’s Smartcart can be used to store cable or at a jobsite where preparing wire pulls on the job site requires heavy reel jacks and a lot of manpower to be successful. The container can be lifted or moved using a forklift; requires less material handling and loss; minimizes jobsite congestion and damage; prevents over-ordering and extra deliveries; and has no setup time (local Graybar staff prepares the car). The Smartcart holds up to 18 Cat. 6A reels (18,000 ft) per cart, versus the six to eight reels of most traditional cable dispensers. The unit has four lockable swivel casters, adjustable/removable shelving for pop-box applications, multiple mounting positions and independently spinning reels. Separately, Graybar offers the SmartReel, designed for large cable spools weighing a ton or more. The company notes that maneuvering reels weighing a ton or more throughout a jobsite requires a lot of manpower, equipment, effort and skill. “With so many resources tied up, how is this impacting your total cost of install?” SmartReel, it noted, is “a portable payout system that makes it simple and safe for one person to move reels up to 5,000 pounds when and where you need them.” Contact: Graybar, www.graybar.com.
Nickel-clad copper line can be used for a very wide range of applications U.S.-based Anomet Products, Inc., reports the company’s KULGRID® line of nickel-clad copper wire and rod. A press release said that pure wrought nickel and copper is processed to form a complete metallurgical bond between the materials, thus allowing full ductility at all diameters. Bending, shaping, stamping, and other types of forming are all possible with the product. 64 | WIRE JOURNAL INTERNATIONAL
Suitable for any application where high conductivity rod or wire is needed, the nickel-clad copper also resists oxidation at elevated temperatures and has all the corrosion resistance of pure nickel, the release said. It is available from 0.010 in. to 1 in. in a standard 27% nickel ratio with a conductivity of approximately 70% IACS. The company’s process allows other nickel to copper ratios to be made, and custom configurations may also include the use of nickel alloys and/or alternate brass/bronze/steel based core materials. The nickel-clad copper is available packaged in rods, coils, or spools depending on customer requirements. The temper is available from annealed through full hard. Anomet also offers complete metallurgical services to ensure product quality. Contact: Anomet Products, Inc., tel. 508-842-3069, info@anometproducts.com, www.anometproducts.com.
Prefeeder can provide constant steady tension for downstream wire processing U.S.-based Schleuniger, Inc., is scheduled to exhibit two new wire processing models at the The Assembly Show later this month in Rosemont, Illinois. A press release said that the company will demonstrate its latest pre- and post-processing machines, the PreFeeder 3200 and CableCoiler 1450. The PreFeeder 3200 is a puller-type prefeeding machine for wire and cable with an outer diameter of up to 35 mm. The prefeeder, made for use with Schleuniger’s cut-and-strip machines, is an economical system that provides constant tension to the downstream wire processing machine. The CableCoiler 1450, which offers fully synchronized, precise wire and cable coiling, is compatible with all Schleuniger cut and strip machines. The company will also demonstrate its Laser Wire Solutions Mercury-4 laser wire stripping machine, which will be running as part of a full in-line wire processing system. The in-line system is the perfect solution for stripping shielded twisted pair cables. The Mercury-4 provides guaranteed nick-free stripping with radial and axial incision capability. The in-line system, which can be controlled via Cayman software, processes wires and cables up to 6 mm and can perform virtually unlimited length end strips or window strips. Finally, Schleuniger will also demonstrate an in-line system featuring a laser wire marker from Tri-Star
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Technologies. The Tri-Star technology—which is fully integrated with Schleuniger Cayman software—can be run in-line with a Schleuniger cut-and-strip machine, and can apply marks anywhere along a wire or cable. The machine prints in any font, size, and orientation and can mark any UV laser markable wires, including Kapton, Tefzel, and Teflon insulated wires and cables. Contact: Schleuniger, Inc., tel. 603-668-8117, sales@schleuniger.com, www.schleuniger.com.
UV device cures fiber optic coatings U.S.-based Phoseon Technology reports that offers revolutionary UV LED curing that offers notable advantages to traditional UV or arc light curing methods. A press release said that manufacturers that have long cured the coating on filaments using UV or arc lights will find UV LED curing method a better choice as it produces faster and more consistent results. “UV LED curing uses a fine-tuned light source that enables better process control, resulting in a superior and more consistent overall product,” said Ed Kiyoi, technical marketing engineer at Phoseon Technology. “That process control leads to higher yields and reduces scrap for manufacturers.” UV LED curing can reduce operation costs and energy usage up to 70%, Kiyoi said. Further, as UV LED curing
does not contain mercury, which is used in arc lights, it is safer for the environment and workplace. “There have been tremendous advancements in coating materials in recent years,” said Kiyoi. “We’re working closely with companies that develop coating materials so we can continue to improve the curing process and adapt our technology to keep pace with coatings advancements.” “While there is an investment in the UV LED curing equipment, and the company may have to change its process to adapt to the new curing equipment, many companies see a return on their investment very quickly,” Kiyoi said. “The adoption rate of UV LED curing is accelerating, and the more companies that change over, the more it influences others to make the change.” Contact: Phoseon Technology, info@phoseon.com, www.phoseon.com.
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OCTOBER 2017 | 65
PATENTS
Patent Update (Cont’d. from p. 29)
Soft dilute-copper alloy wire, soft dilute-copper alloy twisted wire, and insulated wire, coaxial cable, and composite cable U.S. Patent No.: 9,734,937 Patent date: Aug. 15, 2017 Filed: March 16, 2012 Assignee: Hitachi Metals, Ltd., Japan Inventors: Seigi Aoyama, Toru Sumi, Hiromitsu Kuroda, Hideyuki Sagawa Provided are a soft dilute-copper alloy wire and soft dilute-copper alloy twisted wire which have high electrical conductivity and high bending life and can limit disconnection during use compared with oxygen-free copper wire, and also provided are an insulated wire, coaxial cable, and composite cable using the soft dilute-copper alloy wire and soft dilute-copper alloy twisted wire. The soft dilute-copper alloy wire is subjected to annealing treatment by elongation processing of soft dilute-copper alloy material comprising copper and an additive element selected from the group consisting of Ti, Mg, Zr, Nb, Ca, V, Ni, Hf, Fe, Mn and Cr, with inevitable impurities as the balance, wherein the soft dilute-copper alloy wire has an average grain size that is 20 .mu.m or less in a surface layer having a depth of 50 .mu.m from the surface, and an elongation value that is at least 1% higher than the average elongation value of oxygen-free copper wire that has been subjected to the aforementioned annealing treatment.
Power-supply cable and apparatus for manufacturing electric wire used for said power-supply cable U.S. Patent No.: 9,734,931 Patent date: Aug. 15, 2017 Filed: Aug. 19, 2014 Assignee: Hitachi Metals, Ltd., Japan Inventors: Tomohisa Suzuki, Takeshi Terasaki, Fumihito Oka, Hirotaka Eshima, Naofumi Chiwata It is an objective of the invention to provide a high-power supply cable characterized in that even when mounted in a narrow space where the cable undergoes a repetitive bending motion, any undesirable deformation out of the bending plane is small. There is provided a power-supply cable including: an electric wire including an electrical conductor and a resin sheath covering the electrical conductor, the electric wire having a tendency to generate a curl under a no-load condition, the curl having a curling direction, the curling direction being a normal to the curl, the electric wire having one or more longitudinal ends; a connecting terminal disposed at one of the longitudinal ends of the electric wire; and a curling tendency direction
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indicator showing the curling direction, the indicator being disposed along a normal line to the curl of the electric wire.
Shielded cable U.S. Patent No.: 9,728,303 Patent date: Aug. 8, 2017 Filed: Dec. 10, 2015 Assignee: Sumitomo Electric Industries, Ltd., Japan Inventors: Yuto Kobayashi, Hayato Matsushita A shielded cable includes two signal wires, each of which having a signal conductor covered with an insulator, and a shield conductor having a metal clad resin tape spirally wrapped around the two signal wires in a lump. The insulator is configured so that a section thereof is to be deformable by an external force. A residual diameter ratio of the signal wire is 80% or greater and 95% or less when load of 1 kg is applied to the signal wire for 30 minutes.
Wire rod and steel wire having superior magnetic characteristics, and method for manufacturing same U.S. Patent No.: 9,728,332 Patent date: Aug. 8, 2017 Filed: Nov. 9, 2011 Assignee: POSCO, Japan Inventors: Dong-Hyun Kim, You-Hwan Lee, Woo-Gi Shin A wire rod and steel wire having superior magnetic characteristics and a method for manufacturing same, wherein the wire rod and the steel wire can be used in transformers, vehicles, electric or electronic products, or the like which require low iron loss and high permeability. Provided are a wire rod and steel wire having superior magnetic characteristics and a method for manufacturing same, wherein
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PATENTS
the wire rod or the steel wire comprises, by wt %, 0.03 to 0.05% of C, 3.0 to 5.0% of Si, 0.1 to 2.0% of Mn, 0.02 to 0.08% of Al, 0.0015 to 0.0030% of N, and the remainder being Fe and unavoidable impurities. The wire rod and steel wire having directional properties may be provided by a general manufacturing process without using expensive alloying elements and without having to add a manufacturing facility.
Power cable with a thick insulation layer and a method for its manufacture U.S. Patent No.: 9,728,300 Patent date: Aug. 8, 2017 Filed: Feb. 25, 2014 Assignee: Dow Global Technologies LLC, USA Inventor: Timothy Person A power cable comprising a: (A) Conductor, (B) First semiconductor in contact with the conductor; (C) First insulation layer in contact with the first semiconductor; (D) Second semiconductor layer in contact with the first insulation layer; (E) Third semiconductor layer in contact with the second semiconductor layer; (F) Second insulation layer in contact with the third semiconductor layer; and (G) Fourth semiconductor layer in contact with the second insulation layer.
Insulated wire, electrical equipment, and method of producing insulated wire U.S. Patent No.: 9,728,296 Patent date: Aug. 8, 2017 Filed: Feb. 25, 2014 Assignee: Furukawa Electric Co., Ltd., Furukawa Magnet Wire Co., Ltd., Japan Inventors: Makoto Oya, Makoto Onodera, Keiichi Tomizawa An insulated wire having a conductor, a foamed insulating layer containing a thermosetting resin having cells, coated directly or indirectly onto the outer periphery of the conductor and an outer insulating layer containing a thermoplastic resin having a melting point of 240.degree. C. or higher when the thermoplastic resin is a crystalline resin or a thermoplastic resin having a glass transition temperature of 240.degree. C. or higher when the thermoplastic resin is a non-crystalline resin; electrical equipment using the insulated wire; and a method of producing the insulated wire, containing a step of forming a foamed insulating layer by applying a varnish for forming the foamed insulating layer on the outer periphery of a conductor, by generating foams during baking and a step of forming an outer insulating layer by extrusion-molding a thermoplastic resin composition for forming the outer insulating layer on the outer periphery of the foamed insulating layer.
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Cable identification using a unique cable sleeve U.S. Patent No.: 9,726,610 Patent date: Aug. 8, 2017 Filed: April 14, 2015 Assignee: Sumitomo Electric Industries, Ltd., Japan Inventors: Tamer Abuelsaad, John Moore, Singi Rajeshkumar, Robert Wentworth A cable identification system is provided. The cable identification system includes a cable sleeve with some predetermined unique properties. The cable sleeve is adapted to receive a cable therein. The cable includes one or more electrical conductors therein. The cable identification system further includes a portable measuring device configured to detect the predetermined unique properties of the cable sleeve when positioned adjacent the cable at any point along the cable.
Si-killed steel wire rod and spring U.S. Patent No.: 9,725,779 Patent date: Aug. 8, 2017 Filed: Dec. 14, 2015 Assignee: Kobe Steel, Ltd., Japan Inventors: Tomoko Sugimura, Koichi Sakamoto A Si-killed steel wire rod for obtaining a spring excellent in fatigue properties and a spring excellent in fatigue properties obtained from such steel wire rod are provided. In the Si-killed steel wire rod of the present invention, oxidebased inclusions present in the wire rod contain SiO.sub.2: 30-90%, Al.sub.2O.sub.3: 2-35%, MgO: 35% or below (not inclusive of 0%), CaO: 50% or below (not inclusive of 0%), MnO: 20% or below (not inclusive of 0%) and BaO: 0.2-20% respectively, and total content of (CaO+MgO) is 3% or above.
Adhesive tape for jacketing elongate material such as especially cable looms and jacketing method U.S. Patent No.: 9,692,182 Patent date: Aug. 8, 2017 Filed: April 27, 2012 Assignee: tesa SE d., Germany Inventors: Brigitte Korthals, Nicolai Bohm, Dennis Seitzer; Dennis An adhesive tape has a preferably textile carrier and of a pressure-sensitive adhesive which is applied on at least one side of the carrier and is in the form of a dried polymer dispersion. The polymer being synthesized from (a) 5% to 25% by weight, preferably 10% to 22% by weight, of ethylene, (b) 30% to 69% by weight, preferably 40% to 60% by weight, of alkylacrylic ester having C.sub.4 to C.sub.12 alkyl radicals, (c) 20% to 55% by weight, preferably 28% to 38% by weight, of vinyl acetate, (d) 0% to 10% by weight of other ethylenically unsaturated compounds, and
established with the cables (7) at the connection parts (5b) located on the seabed. In other words, the cables (7) are installed on the seabed.
Undersea cable, undersea cable installation structure, and method for installing undersea cable U.S. Patent No.: 9,722,406 Patent date: Aug. 1, 2017 Filed: June 13, 2016 Assignee: Furukawa Electric Industries, Ltd., Japan Inventors: Hiroki Manabe, Toru Kagoura, Takahiro Sasaki, Yoshihiro Shimada, Takeharu Yamaguchi Ocean floating installations (1) are disposed on the ocean. The ocean floating installations (1) float on the ocean with the lower part of the ocean floating installations (1) being fixed to the seabed by mooring ropes (11). Each of the ocean floating installations (1) is connected at a connection part (5a) to a cable (3), which is a first cable. Each of the cables (3) is connected at a connection part (5b) to a cable (7), which is a second cable. In other words, the ocean floating installations (1) are connected to each other by the cables (3) and the cable (7). A connection is
Wire for deep water transmission U.S. Patent No.: 9,721,696 Patent date: Aug. 1, 2017 Filed: Aug. 21, 2015 Assignee: Materion Corporation, USA Inventors: Nielsen, Jr.; William Nielsen, Jr., Diane Nielsen; Walter Maxwell An electrically conductive wire for deep water transmission includes a first wire portion and a second wire portion. The first wire portion makes up one end of the wire, and is formed from a first metal. The second wire portion is formed from a second metal. The first metal has a higher ultimate tensile strength than the second metal. The first wire portion is used to support the weight of the second wire portion, thereby allowing the electrically conductive wire to be used in underwater or subsea power cables which may be freely suspended from their origin for providing electricity to electrical devices located in deep water or ultra-deep water.
REELS AND DRUMS Metal reels for wire and cable. Process and transport.
HANDLING EQUIPMENT Take apart reels for coil’s production. All the necessary accessories for reels and coils handling.
GMP Slovakia s.r.o., Pribenik - Slovakia sales@gmp-slovakia.com www.gmp-slovakia.com
OCTOBER 2017 | 69
PATENTS
the pressure-sensitive adhesive comprising between 15 and 100 parts by weight of a tackifier (based on the mass of the dried polymer dispersion).
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Contents lists available at ScienceDirect
Fusion Engineering and Design journal homepage: www.elsevier.com/locate/fusengdes
Cyclic load effect on round strands made by twisted stacks of HTS tapes N. Bykovsky ∗ , D. Uglietti, R. Wesche, P. Bruzzone EPFL-SPC, Superconductivity Group, PSI, CH-5232 Villigen, Switzerland
h i g h l i g h t s • Investigation of the cyclic load degradation in the HTS cable prototype is performed. • Results of transverse load fatigue tests on the HTS strands at 77 K are presented. • Design of the new HTS cable prototype for the DEMO CS coils is discussed.
a r t i c l e
i n f o
Article history: Received 30 September 2016 Received in revised form 28 March 2017 Accepted 12 April 2017 Available online xxx Keywords: HTS high current cables Coated conductors Cyclic load
a b s t r a c t Various DC tests performed recently with full-size 60 kA HTS cable prototypes in the EDIPO test facility demonstrated that proposed design of HTS strand at Swiss Plasma Center (SPC) – stack of HTS tapes twisted and soldered between two copper profiles – is applicable for high-current fusion cables, but improvement of the strand mechanical properties against the cyclic loading is still needed. Based on experimentally obtained correlation between the performances of cable prototypes at different operating conditions, further investigation of cyclic transverse load on the strand performance was performed at 77 K. Aiming to obtain a strand design able to withstand a continuous cyclic load operation of some thousand cycles, influence of the strand geometry and tape’s manufacturer has been studied. Cyclic load has been applied up to 1000 cycles for straight and bent samples at the load amplitudes up to 4 MPa. Based on the obtained data, next design of HTS cable prototype will be discussed. © 2017 The Author(s). 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/).
1. Introduction Two test campaigns have been performed recently with the 60 kA HTS cable prototypes at SPC. Initial measurements of the current-sharing temperature demonstrated an excellent agreement with the expected cable performance for the operating current from 20 kA to 70 kA and in the background magnetic field up to 12 T [9]. During the cycling test, where the field was set at 12 T and the current was applied in a cyclic manner from 0 kA to 50 kA, a gradual decrease of the performance with the number of cycles has been observed [1]. After 2000 cycles this fatigue behavior results in ≈10% and ≈20% performance drop for the SuperPower and SuperOx prototypes respectively. Further inspection of the SuperOx prototype revealed that the Lorentz force acting on the strands in the cable is the key factor of the degradation. Thus, the HTS cable layout is feasible for application in fusion magnets, but design of the strand
∗ Corresponding author. E-mail address: nikolay.bykovsky@psi.ch (N. Bykovsky).
still requires alterations in order to withstand the electromagnetic cyclic load during the cable operation.
2. FEM analysis In order to formulate a scope of the work, let first see results of the corresponding mechanical analysis. Mechanical stresses for a geometry of the cable prototypes have been calculated in a 2D ‘plain strain’ FEM model similar to the one in [3]. The model also includes steel jacket domain with the Young’s modulus 207 GPa. Each stack of the cable carries I = 3 kA at B = 12 T background field directed along the wide side of the cable. The self-field produced by the cable is also taken into account. Considering the Lorentz body forces acting on the stack domain and assuming zero-displacement for the bottom side of the jacket, distributions of the von Mises stress in the cable space are shown in Fig. 1 for the different orientations of the stacks in the cable. Average von Mises stress in the stack domains is presented in Fig. 2. The labels of curves and strand numbers correspond to those in Fig. 1. A rough estimation of the transverse load as 2IB/D is close to the average stress obtained for the bottom layer of stacks (strand
http://dx.doi.org/10.1016/j.fusengdes.2017.04.050 0920-3796/© 2017 The Author(s). 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/).
Please cite this article in press as: N. Bykovsky, et al., Cyclic load effect on round strands made by twisted stacks of HTS tapes, Fusion Eng. Des. (2017), http://dx.doi.org/10.1016/j.fusengdes.2017.04.050
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Fig. 1. Distribution of the von Mises stress in the cable operating at 60 kA in 12 T background field for the different stacks orientations.
Fig. 3. Experimental setup for the cyclic transverse load test at 77 K.
Table 1 Parameters of strands used for the sample manufacturing. Tape’s manufacturer
SuperOx
SuperPower
4 110 16 6.2 4.3/2 ≈1600
3 93 26 6 3.3/3 ≈1000
Cross-section
Width of tape w, mm Thickness of tape dt , m Number of tapes n Diameter D, mm Slot width/height, mm Strand Ic at 77 K/sf, A
Fig. 2. Average von Mises stress in the stacks. See Fig. 1 for definition of the curve labels and strand numbers.
numbers from 11 to 20) of the (c) case, where D = 6.2 mm is the strand diameter. Significantly higher stress is obtained for the (a) case, but the values stay below 20 MPa. Comparing the calculated stress with the performance of the single strands under the transverse load [3], significant degradation is not expected during the cable operation. This leads to an assumption that the obtained performance degradation of the prototypes is not related to the stress magnitude, but could be linked with the fatigue properties of strands. Though a very stable performance at 77 K of the single ReBCO tapes was reported in the tensile [5,8,6] and transverse load fatigue tests [4,7], the more sophisticated stress distribution in a multi-tape strand may result in a peel stress in the superconducting layer, what reduces drastically the fatigue properties of the strand. Study of the fatigue phenomena on the strands was performed on the experimental assembly that described in the following section. Obtained results on a set of SuperOx and SuperPower strands for different magnitudes and directions of the transverse load will be presented and discussed in Section 4.
3. Experimental details The original press assembly that was used in the preliminary transverse load tests of the strands [3] was upgraded for an automatic control, see Fig. 3. Signal from the piezo sensor is used as a feedback for control of the DC motor. Worm gear installed on the top plate of fiberglass support serves as a reduction drive (20:1) for the motor and also prevents release of the applied force at a system idle. During the system operation the strand in the press is immersed in a liquid nitrogen bath. In order to reduce heat transfer from the cooling region of the system, the steel shaft is composed of three pieces with a hollow part in the center. External force is applied in a cyclic manner from 0 to the maximum value F corresponding to the pressure pmax = F/(lD), where l = 15 mm is the length of the anvil. Note that actual body force acting on strands in the cable is simulated by the contact force between the strand and anvil. Two types of strands that have been selected for the cyclic load tests are presented in Table 1. The SuperOx strands correspond to those used in the 60 kA cable prototype and aimed to reproduce the fatigue properties obtained during the cable measurements [1]. The SuperPower strands composed of 3 mm wide tapes have demonstrated promising results in the bending and transverse load tests
Please cite this article in press as: N. Bykovsky, et al., Cyclic load effect on round strands made by twisted stacks of HTS tapes, Fusion Eng. Des. (2017), http://dx.doi.org/10.1016/j.fusengdes.2017.04.050
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3
Fig. 4. Photo of one strand used in the measurements.
[3] and were selected for the measurements to further validate as a possible candidate for the next cable prototype. In total 6 strands have been manufactured: 3 SuperOx and 3 SuperPower. One of the SuperPower strands has non-annealed copper profiles, while the other samples were manufactured with the ones preliminary annealed at 300 ◦ C, what strongly reduces the yield strength of copper. Aiming to better reproduce the mechanical state in the cable, two samples were also bent before the cyclic loading at radius ≈36 mm, what corresponds to strand bending around the cable edge in the prototypes [2]. Each sample is about 30 cm long and contains 4 regions with the voltage taps at a distance 2 cm to be tested in the press, see Fig. 4. The transverse load was applied on the region from 0 to pmax up to 1000 cycles, with intermediate measurements of the strand Ic as a function of number of cycles nc at zero and maximum load pmax . Tolerance for the applied load pmax has been set conservatively to ±1 MPa in order to increase the frequency of operation. After the tuning of PID control, the system can operate up to 6 cycles per minute, what allows to perform a full cycling test on the strand region within one day. The maximum force that can be transmitted in the assembly is ≈10 kN, what corresponds to pmax ≈ 110 MPa. 4. Results and discussion Obtained test results are normalized to the critical current of the strand measured after the first load cycle Ic (1) (see typical values in Table 1). The data are summarized in Fig. 5 (estimated error bar is ≈0.5%). Degradation of the strand performance during the cyclic loading has been observed. For the different load directions studied on the straight SuperOx strands (0◦ vs 90◦ ) similar results have been obtained. Applied bending at 360 mm radius on the SuperOx strand does not cause weakening of the fatigue properties for the cyclic load at 20 MPa and 30 MPa, but at 40 MPa the strand performance degraded by 5% already at 800 cycles. Nevertheless the Ic evolution of the SuperOx cable prototype during the cycling test [1] was not reproduced in the performed measurements of the SuperOx strands. On top of that, there is no data correlation for the different pressure amplitudes: the loading at 20 MPa results typically in the higher degradation than at 30 MPa. Possible reasons of these issues will be addressed below in this section. The SuperPower strands with the annealed copper profiles perform weaker in the measurements than the SuperOx ones. Higher degradation has been obtained on both the straight and bent samples, with a higher impact of the bending on the fatigue properties. Similar to the SuperOx strands, no data correlation for the different pmax has been also observed: for the bent SuperPower sample better fatigue properties were obtained at 30 MPa than at 20 MPa. On the other hand, the sample with the non-annealed copper profiles has demonstrated a very stable performance for the load amplitudes up to 40 MPa: strand Ic was almost not affected after 1000 load cycles. As a preliminary conclusion, annealing of the copper profiles could be responsible for the strand performance degradation in the cyclic load measurements.
Fig. 5. Evolution of Ic (at 77 K/sf) against the number of cycles nc for SuperOx (top plot) and SuperPower strands (bottom plot) for different amplitudes of cyclic load pmax . Each individual color corresponds to one sample tested at selected bending and direction of the transverse load.
Fig. 6. Cross-section of the straight strands after 1000 load cycles (90◦ load, pmax = 20 MPa): left – SuperOx, center – SuperPower, right – SuperPower (nonannealed copper). Dashed circles are drawn from the strand centers; diameter of the left circle is 6.2 mm, other two – 6 mm.
Comparing Ic (1) to the value measured before the loading, a noticeable irreversible degradation for some of the tested regions has been obtained (up to 5%). This may indicate a presence of voids in the cross-section of the strand. In order to validate this assumption the strands were cut after the measurements at the locations of the test regions. The corresponding cross-sections that were subjected to 90◦ load at pmax = 20 MPa of the straight SuperOx and SuperPower (with annealed and non-annealed copper profiles) strands are presented in Fig. 6. All the pictures show an issue with the strand manufacturing: the slot space is not completely filled with solder. This leads to a higher stress concentration at the location of voids during the transverse loading. Comparing the cross-sections of the SuperPower strands, one can see effect of the annealing: the annealed pro-
Please cite this article in press as: N. Bykovsky, et al., Cyclic load effect on round strands made by twisted stacks of HTS tapes, Fusion Eng. Des. (2017), http://dx.doi.org/10.1016/j.fusengdes.2017.04.050
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Table 2 Geometry parameters of the cable designs presented in Fig. 7. Cable
Round
Flat
Width of tape, mm Strand diameter, mm Annealing of copper profiles Number of strands Thickness of core, mm
4.8 10.0 No 6 10
3.3 7.0 Yes 12 5
Cable space, mm2
710
750
Fig. 7. Cross-section of the HTS cables for CS coil: left (‘round’) – 4.8 mm width tapes, non-annealed copper profiles; right (‘flat’) – 3.3 mm width tapes, annealed copper profiles.
files, being a ‘softer’ material, have a highly deformed shape, while the non-annealed ones are not deformed. It agrees with a distinction in the test results between the two SuperPower samples (see Fig. 5). Nevertheless by improving the strand manufacturing process, effect of the copper annealing on the fatigue properties could be significantly reduced if voids will not be presented in the strand volume. A local non-homogeneity of the mechanical properties of the annealed profiles could be present, because the temperature distribution along the profiles during the annealing process was not precisely controlled. This would explain the cases when better fatigue properties were obtained at higher pmax on the SuperOx and SuperPower strands. Since the performance evolution of the SuperOx cable prototype was not reproduced in the cyclic load measurements, further study of the cyclic transverse load for the annealed and non-annealed copper profiles will be performed with new HTS cable prototypes. Preliminary details over the possible cable designs will be discussed in the next section. 5. HTS cable prototypes Next HTS cable prototypes at SPC are meant to demonstrate their applicability for the central solenoid (CS) coils of fusion magnets. In a layer winding design of the CS coil with a superconductor grading (HTS is envisaged in high field section, Nb3 Sn – intermediate fields, NbTi – lowest fields), use of HTS conductors in the innermost layers at 1.9 m radius allows to reduce external radius of the CS module to 2.8 m (see details of the SPC coil design for EUROfusion in [10]). For the conductors operating at 53.6 kA the estimated peak magnetic field in the CS midplane is ≈18 T. Hence, for the cable test in SULTAN at 10.8 T (peak field of the facility) the cables should be designed for the critical current ≈88 kA, assuming 13% current margin and 1.43 scaling factor from 18 T to 10.8 T. Preliminary design study of the cable prototypes composed of the annealed and non-annealed copper profiles was carried out for the HTS tapes produced by Shanghai Superconductor Technology (SST) company (width of the tapes: 3.3 mm or 4.8 mm, thickness: 60–100 rmmum, current density at 4.2 K/12 T: 55–90 A/mm). Obtained parameters for the two cable designs are summarized in Table 2; also see corresponding illustrations in Fig. 7. Several cable aspects have been addressed in the presented designs:
• The cable space has been balanced for the two prototypes. • While a flat geometry provides better bending properties for the cable, applying the same twist-pitches for the cables leads to a round geometry for the cable with non-annealed profiles in order to increase bending radius of the strand in the cable. • In order to obtain similar current capacity for the two cables, total width of HTS tapes in the cross-section (i.e. if all the tapes were arranged side by side) should be adjusted. Depending on the SST tape current density, required total tapes’ width for a 88 kA cable is from 0.9 m to 1.5 m. In the ‘round’ cable with 4.8 mm width tapes it can be achieved by using from 33 to 49 tapes per strand, in the ‘flat’ cable with 3.3 mm width tapes – from 25 to 37 tapes per strand. As a result, the two cable designs have a similar geometry and represent a different arrangement of the superconductor. Thus, effect of the copper annealing on the cable performance can be revealed directly from the measurements in SULTAN. Six additional copper rods of 3.4 mm diameter might be used in the ‘round’ cable between the strands and steel jacket to increase the copper cross-section in the cable and to better redistribute the mechanical stresses (i.e. lower the stress in the stacks). 6. Summary Influence of the cyclic transverse load on the round HTS strands has been studied at 77 K. While the Ic degradation during the cycling has been observed, performance evolution of the SuperOx cable prototype was not reproduced in the measurements. Cross-section analysis of the samples after the mechanical tests revealed the issue with the manufacturing process, which should be improved especially for the strands composed of copper profiles with a spit-line along the c-axis of the stack. Performance of the strand with nonannealed copper profiles was not affected during the cyclic loading. Effect of the profile annealing on the cable properties will be further investigated during the test of HTS cable prototypes in the SULTAN test facility at SPC. Acknowledgments The authors thank the Paul Scherrer Institute (PSI) for the technical support. This work has been carried out within the framework of the EUROfusion Consortium and has received funding from the Euratom Research and Training Programme 2014–2018 under grant agreement No 633053. The views and opinions expressed herein do not necessarily reflect those of the European Commission. References [1] D. Uglietti, N. Bykovsky, K. Sedlak, B. Stepanov, R. Wesche, P. Bruzzone, Supercond. Sci. Technol. 28 (2015) 124005. [2] N. Bykovsky, D. Uglietti, K. Sedlak, B. Stepanov, R. Wesche, P. Bruzzone, Supercond. Sci. Technol. 29 (2016) 084002. [3] N. Bykovsky, D. Uglietti, R. Wesche, P. Bruzzone, IEEE Trans. Appl. Supercond. 26 (2016) 4201207. [4] A. Mbaruku, J. Schwartz, IEEE Trans. Appl. Supercond. 18 (2008) 1743–1752. [5] M. Sugano, Y. Yoshida, M. Hojo, K. Shikimachi, N. Hirano, S. Nagaya, Supercond. Sci. Technol. 21 (2008) 054006. [6] H.-S. Shin, M.J. Dedicatoria, Cryogenics 51 (2011) 237–240. [7] J.W. Ekin, S.L. Bray, N. Cheggour, C.C. Clickner, S.R. Foltyn, P.N. Arendt, A.A. Polyanskii, et al., IEEE Trans. Appl. Supercond. 11 (2001) 3389–3392. [8] H.-S. Shin, A. Gorospe, Z. Bautista, M.J. Dedicatoria, Supercond. Sci. Technol. 29 (2016) 014001. [9] N. Bykovsky, D. Uglietti, R. Wesche, P. Bruzzone, IEEE Trans. Appl. Supercond. 25 (2015) 4800304. [10] R. Wesche, N. Bykovsky, X. Sarasola, K. Sedlak, B. Stepanov, D. Uglietti, P. Bruzzone, Fusion Eng. Des. (2017), http://dx.doi.org/10.1016/j.fusengdes. 2017.04.052 (in press).
Please cite this article in press as: N. Bykovsky, et al., Cyclic load effect on round strands made by twisted stacks of HTS tapes, Fusion Eng. Des. (2017), http://dx.doi.org/10.1016/j.fusengdes.2017.04.050
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TECHNICAL PAPERS Implications of Higher Data-Rate Ethernet Over Prior Standard Twisted-Pair Data Cabling David C. Hess CORD DATA Wyomissing, Pennsylvania, USA +1-610-698-4790 · davecarlhess@outlook.com
pair data cabling systems, e.g. standards from IEEE 802.3, ISO/IEC SC25, and TIA TR42.
Abstract New Ethernet standards are under development, which provide two to five times higher data rates than the original Ethernet data rates, while operating over the prior generation of standard unshielded twisted pair cabling. The primary purpose is to gain full utilization of the installed base of Category 5e and Category 6 structured cabling. The 10GBASE-T Ethernet technology, originally specified for operating at 10Gb/s over 100m of Category 6A cabling, has been adapted to operate at 2.5Gb/s over Category 5e cabling and 5Gb/s over Category 6 cabling. Although the existing Category 5e and Category 6 cabling standards cannot be changed, actual cabling can be requalified for the new higher data-rates by re-evaluating certain transmission parameters. The requalification guidelines use practical techniques to determine the effective data capacity of a particular channel. The use of these techniques implies the means to determine the potential rate, reach and margin for any cabling channel implementation.
According to the standard channel model, information capacity limitations may be expressed in terms of bandwidth, margin or reach. In this paper, the effect on the reach limitations, due to the combination of alien-crosstalk and common-mode noise, is studied for various practical channel implementations. A comparison is made between the reach limitation figures for various channel classes, derived from the information capacity model. Reach reduction predictions are based on the attenuation to alien-crosstalk ratio model. The results are based upon practical cabling products and derived from demonstrated behavior, thus providing verification of the baseline assumptions. The models used to generate the views provide essential system and component design tools. Recommendations are made for simplification of the model and variables, while maintaining sufficient precision for component design and analysis.
Keywords: twisted-pair; cable; Category 5e; Category 6;
2. Background 2.1 Data communications interface standards
Category 6A; Category 7A; cabling; channel; Class-D; Class-E; Class-EA; class-FA; Shannon; capacity; model; margin-tocapacity; ACR; SNR; data; rate; reach.
Standard data communications channels transmission parameters are specified according to international standards. The standards are developed by various standards development organizations (SDO), such as IEEE, ISO/IEC, and TIA.
1. Introduction New IEEE 802.3 physical interface specifications (PHYs) have been added to support 5Gb/s and 2.5Gb/s over Category 6 and Category 5e cabling, respectively.
2.1.1 IEEE SA (Institute of Electrical and Electronics Engineers, Standards Association)
Renewed interest in twisted-pair, balanced cabling is the result of two very important trends, which have emerged to work together for a key application. •
Indoor, enterprise wireless communications applications infrastructure is benefitting considerably from new efficient wired “backhaul” links.
•
Multi-gigabit LAN (local area network) cabling is enabling all forms of broadband communications services distribution within the enterprise.
The international group responsible for developing the Ethernet® wired, and WiFi® wireless, data communications standards, for local area network and metropolitan area network (LAN/MAN) is the IEEE-SA 802 LAN/MAN Standards Committee. The 802.3 sub-committee publishes the Ethernet connectivity standards, which are used for wired internet data transport used between nearly all microprocessor based equipment. The Ethernet physical interfaces (PHY) standards, which cover all cabling media types, includes the basic specifications and references for twisted-pair cabling links. Ethernet comprises a full-featured generic example for twisted-pair media; it utilizes complex modulation, active equalization and noise reduction systems, and forward error correction (FEC).
10GBASE-T has become the mainstream wired LAN edge-link connectivity, which uses standard Category 6A balanced cabling technology, supporting a 10Gb/s data rate over links reaching up to 100m in length. Already forward adapted to 25Gb/s and 40Gb/s, the 10GBASE-T modulation and coding scheme has recently been backward adapted to two more new PHYs, i.e. 5Gb/s over Category 6 and 2.5Gb/s over Category 5e. The standard channel model has been updated according to recent refinements, which are covered in the new balanced cabling link standards.
As of this writing the latest version of IEEE802.3 [1] and amendments cover:
This paper includes an overview of the related international standards, which are published or under development, for twisted-
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2.5G/5GBASE-T [3] IEEE 802.3 (bz) 2016, PHY clause 126, runs over Class D / Category 5e (CAT5e) 100MHz and Class E / Category 6 (CAT6) 250MHz cabling channels respectively (see below).
•
10GBASE-T, [1] IEEE 802.3 (an) 2006, PHY clause 55, runs over Class EA / Category 6A (CAT6A)
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2.1.3 TIA (Telecommunications Industry Association)
25G/40GBASE-T, [2] IEEE 802.3 (bq) 2016, PHY clause 113, runs over new Class I / Category 8.1 (CAT8.1) and Class II / Category 8.2 (CAT8.2), 2GHz, cabling channels (see below).
TIA Standards committee TR42 covers IT building network cabling systems, for Enterprise, Datacenter, Industrial, Residential and Intelligent buildings. These regional standards are focused on US and North America building and electrical construction guidelines. TIA-568 premises cabling standards series part 2, including TIA-568-C.2 [8] and TIA-568-C.2-1 addendum 1 [9], covers twisted-pair Category cabling channels and components; e.g. CAT5e, CAT6, CAT6A and CAT8 (CAT8.1 equivalent).
2.1.2 ISO/IEC (International Standards Organization / International Electrotechnical Commission) ISO/IEC JTC1 SC25 WG3 1 is the international standards committee covering interconnection of microprocessor based IT equipment. All building network cabling systems are standardized within the ISO/IEC 11801-X series. ISO/IEC 11801-1 [4] covers generic cabling and all of the media types, which are referenced by the other standards in the series, which cover the implementations within the various building environments.
The TIA-568 series cabling standards are harmonized with and conform to the ISO/IEC 11801-1 [4] cabling standards.
2.2 Data communications interface modeling and simulation Cabling channel model According to the standard balanced cabling channel model, information capacity may be equivalently expressed in terms of rate, reach or margin. In this paper, reach limitations are determined for a given margin, which is determined from biterror-rate (BER), for various data-rates and for various standard channel implementations. Evaluations of signal-to-noise-ratio parameters are covered in new cabling standards and technical reports, which are under development for future standards. New specifications covering signal power levels and spectral noise power levels, which are associated with the new higher speeds, are now provided within the Ethernet standards. This paper uses standardized analytical methods to simulate twisted-pair data channels for the purpose of calculating rate, reach and margin. Various views of the results are presented in various comparisons, e.g. margin-to-reach, and rate versus reach for a given margin.
The cabling requirements cited in this paper are based on the ISO/IEC 11801-1 standard specifications. ISO/IEC 11801-1 Generic cabling standard, includes the detail specification for the twisted-pair channel classes and component categories included in the standard reference implementations; e.g. Class-D/CAT5e, Class-E/CAT6, Class-F/CAT7, Class-EA/CAT6A, Class-FA/CAT7A, Class-I/CAT8.1, and Class-II/CAT8.2. New technical reports extend the cabling standards to support new applications: •
•
•
1
ISO/IEC/TR 11801-9901, 2014-10 [5] , technical report covers the investigation of the channel capacity for 40GBASE-T operation over Class-I/CAT8.1, and Class-II/CAT8.2, 2GHz, shorter-reach cabling channels. The technical report provides the recommended standard method for calculating the channel signal-tonoise-ratio (SNR). A channel capacity model based on Shannon capacity is also covered.
Three important new specifications have been introduced into the IEEE 802.3bz 2.5G/5GBASE-T PHY standard for link operation over Class D/CAT5e and Class E/ CAT6:
ISO/IEC/TR 11801-9904, draft DTR 2016-07 [6] , technical report covers the investigation of the channel capacity for 2.5G/5GBASE-T operation over Class-D/CAT5e, 100 MHz; and Class-E/CAT6, 250 MHz, cabling channels. The technical report provides the recommended standard method for calculating the channel signal-to-noise-ratio (SNR). A channel capacity model based on the 802.3bz ALSNR calculation is also covered. ISO/IEC/TR 11801-9905, 2016-06 [7] , technical report covers the investigation of the channel capacity for 25GBASE-T operation over Class-EA/CAT6A, and Class-FA/CAT7A, 1GHz, shorter-reach cabling channels. The technical report provides the recommended standard cabling channel implementations needed to achieve the signal-to-noiseratio (SNR) requirements.
This is the first time that a new IEEE 802.3 PHY specification for BASE-T, twisted-pair, has established new speeds, i.e. 2.5Gb/s and 5Gb/s; all prior BASE-T speeds have been established by other media types.
2.
A basic noise figure has been included in the form of a power-sum noise term, which establishes the lower bound for SNR characterization.
3.
A basic margin figure has been included, which establishes the relative limit for conformant operation in terms of SNR, i.e. to achieve the required BER.
These additions to BASE-T provide considerable insight for verification of the cabling channel model and transmission parameters. Together with more new BASE-T data rates, the new term MultiGBASE-T was added to comprise the specifications for multiple operational speeds. The standard cabling channel model and verification measurements developed for 10Gb/s have been applied to verify the reach achievable for installed and legacy twisted-pair balanced cabling channels., within fully configured installations. The 10GBASE-T channel is essentially alien-crosstalk limited, thus the essential new feature added to Category 6A UTP cabling was the alien-crosstalk loss parameters requirements. The overwhelming contributor to the noise figure for a Cat 6A channel
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500MHz or Class FA / Category 7A (CAT7A) 1000MHz cabling channels (see below).
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is alien-crosstalk, which is the primary limitation to the information carrying capacity of the channel.
Table 1, Basic cabling channel parameters
During the 40 Gb/s twisted-pair Ethernet feasibility studies, channel and capacity modeling was used extensively to evaluate possible solutions. Methods based on the traditional attenuationto-crosstalk-ratio (ACR) model continue to be practical and effective.
Acronym
Parameter
IL
Insertion Loss
RL
Return Loss
PSNEXT
Power-Sum Near-End Cross-Talk loss
PSACRF (= PSFEXT - IL)
Power-Sum Attenuation to Cross-Talk Ratio, Farend
This paper is focused on the new MultiGBASE-T, applications designed to run over the range of standards, Class-D/CAT5e, Class-E/CAT6, Class-EA/CAT6A and Class-FA/CAT7A cabling. The current cabling channel performance requirements are covered in ISO/IEC 11801-1 [4] and TIA-568C.2-1 [9]. CAT5e, CAT6, CAT6A (and CAT7A) components requirements are specified for constructing reference implementation channels, with 4 connectors, up to 100m length. A special case for 50m length is also considered. Transmission parameters are extrapolated up to 2000 MHz for the purpose of the visualization.
PSANEXT
Power-Sum Alien Near End Cross-Talk loss
PSAACRF (= PSFEXT - IL)
Power-Sum Alien Attenuation to Cross-Talk Ratio, Far-end
TCL
Transverse Conversion Loss (near-end, unbalance attenuation)
TCTL
Transverse Conversion Transfer Loss (far-end, unbalance attenuation)
CAN
Coupling attenuation, near-end
CAF
Coupling attenuation, far-end
Illustrations show the minimum performance necessary to achieve the maximum 10-12 bit-error-rate (BER), which is needed to support standard range of MultiGBASE-T links.
NOTE: while PSACRF is used to specify cabling channel limits, PSFEXT is used in the channel noise model, likewise for PSAACRF and PSAFEXT. PSFEXT and PSAFEXT are derived from the measured parameters, PSACRF and PSAACRF, respectively.
3.1 Cabling transmission parameters
NOTE: PS(CAN+CAF) ≈ PSCMCL
Various cabling parameters affect channel capacity. The channel transfer function (frequency response, dBm) determines the channel capacity (bits-per-second, b/s). The results of this paper are derived from the transmission and crosstalk parameters:
NOTE: Propagation delay and delay skew parameters are not included in SNR calculations
3. MultiGBASE-T cabling channels SNR models
•
Internal transmission parameters: (near-end) Return loss (RL) and (far-end) Insertion loss (IL)
•
Internal crosstalk parameters: Near-end crosstalk loss (NEXT) and Far-end crosstalk loss (FEXT & ACRF)
•
External crosstalk parameters: Near-end alien-crosstalk loss (ANEXT) and Far-end alien-crosstalk loss (AFEXT & AACRF)
•
Internal mode-conversion parameters: Transverse Conversion Loss (TCL) and Transverse Conversion Transfer Loss (TCTL)
•
External
NOTE: Most parameters have upper bounds and some have lower bounds, which are specified for measurement limitations, however the bounds are not applied to these parameters in the SNR calculations
3.2.1.1 Signal loss Signal loss is determined primarily by the attenuation, which is mainly composed of conductor loss from resistance, based on conductor size and length. Dielectric loss has a secondary effect. The insertion loss (IL) of the channel is determined from the power sum of the cascaded channel components’ attenuations and reflection losses. •
mode-conversion parameters: Coupling attenuation (CA). The basic noise term, integrated common-mode-coupling-loss (PSCMCL), comprises near-end and far-end CA.
3.2.1.2 Noise figure The total noise figure for the channel is determined by the powersum of the major noise contributors:
A single mode-conversions parameter equivalent has been included in the updated capacity calculations. The full set of mode-conversion parameters are included here to illustrate the complete parameters context: See NOTE 6.4: Relationship of alien-crosstalk to couplingattenuation.
•
Signal reflections are characterized by the channel return-loss (RL) specifications. Although RL is a transmission parameter, it is treated as noise and included as a contributor to the power-sum noise figure.
•
Internal crosstalk loss, near-end (PSNEXT) and far-end (PSFEXT), are the primary sources of internal channel noise, i.e. channel self-crosstalk between the 4 pairs carrying the 4 parts of the MultiGb/s data link.
•
External or “alien” crosstalk loss, near-end (PSANEXT) and far-end (PSAFEXT), are a primary source of external channel noise, i.e. external crosstalk from nearby channels carrying other data links’ signals that interfere with a particular channel.
3.2 Channel model 3.2.1 Signal-to-noise-ratio (SNR) dB Signal to noise ratio is normally expressed in dB, as the difference between the signal power level dB mW and the power-sum of the noise contributors’ relative power levels dB mW. The basic cabling channel parameters, which are controlled by the standards, combine to determine the channel SNR. These parameters are listed in Table 1.
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The total channel IL over frequency determines the signal level frequency response of the channel.
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See NOTE 6.2 for details on the capacity and margin calculations.
4.2.2 Margin-over-reach From the cabling point-of-view, a more practical expression for Channel margin is the difference between the channel capacity and the signal volume, in dB over reach, for a given bandwidth.
Figure 4, Margin-to-capacity over frequency is calculated for Class-D/CAT5e, Class-E/CAT6, EA/CAT6A, and Class-FA/CAT7A, 100m channel implementations. Figure 6, Margin-to-capacity over reach example is calculated for the channel implementations: 5GBASE-T over Class-D/CAT5e & Class-E/CAT6, and 25GBASE-T over EA/CAT6A & Class-FA/CAT7A. An alternative view, reach over frequency for a given margin, provides a visualization of how the variation of rate (BW frequency) affects the reach for a given margin, for a given link implementation.
Figure 5, Margin-to-capacity over frequency is calculated for Class-D/CAT5e, Class-E/CAT6, EA/CAT6A, and Class-FA/CAT7A, 50m channel implementations. More channel capacity provides more margin above the minimum required data-rate for the application, which is expressed as margin-to-capacity. More capacity provides: •
More throughput (higher data rate, bits-per-second, b/s)
•
More reach (longer length, meters, m)
•
Less error (lower bit-error-rate, BER, 10-12 maximum)
Figure 7, Reach over Bandwidth for a given Margin calculated for the channel implementations: 2.5GBASET over Class-D/CAT5e, 5GBASE-T over Class-E/CAT6, 10GBASE-T over EA/CAT6A, and 25GBASE-T over Class-FA/CAT7A.
There is similar margin for 25Gb/s running over 50m CAT7A as there is for 5Gb/s running over 50m CAT6. Albeit small, there is some margin for 25Gb/s running over 50m CAT6A, which implies comfortable margin is available for reaching 20m or 30m.
5. Conclusions
For this analysis, based on various PHY baseline assumptions [6], the minimum effective margin, after enhancements, needed for reliable operation of 10GBASE-T is about 28 dB. NOTE: BER, 10-12 for DSQ128 (7b/Hz) modulation needs 23dB margin; the specification uses 28dB, with 5dB unallocated margin.
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Margin-to-capacity over reach still provides an accurate and effective means to evaluate and compare channel solutions for applications with specific reach objectives.
•
The traditional metric for cabling channel performance, attenuation-to-crosstalk-ratio, ACR, continues to provide a suitable, intuitive model for approximating cabling channel capacity.
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Table 3, Basic cabling channel parameters
6.1.1 Channel parameters definitions and formulas
Parameter
Formula Coefficients
Acronym
Class-D/CAT5e
Class-E/CAT6
f= MHz
100
250
1.05(A√f+Bf+C/√f)+4D√f
IL
1.9108, 0.0222, 0.2, 0.04
1.82, 0.0169, 0.25, 0.02
RL
A1-B1(log(f)), 1≤f<C1; A2-B2(log(f)), C1≤f<C2; … An-Bn(log(f)), Cn-1≤f<Cn
RL
17, 0, 20; 30, 10, 100
19, 0, 10; 24, 5, 40; 32, 10, 250
PSNEXT
-20log((10^(A1-B1(log(f)))/-20)+E1(10^(C1D1(log(f/F1)))/-20)), 1≤f<F1; … -20log((10^(An-Bn(log(f)))/-20)+En(10^(CnDn(log(f/Fn-1)))/-20)), Fn-1≤f<Fn; …
PSNEXT
62.3, 15, 80, 20, 2, 100
72.3, 15, 90, 20, 2, 250
PSACRF (= PSFEXT - IL)
60.8, 20, 72.1, 20, 4, 100
64.8, 20, 80.1, 20, 4, 250
PSANEXT
n/s
n/s
PSAACRF (= PSFEXT - IL)
n/s
n/s
TCL
53, 15, 30; 60.3, 20, 100
53, 15, 30; 60.3, 20, 250
TCTL
30, 20, 30
30, 20, 30
40, 0, 100: 80, 20, 100
40, 0, 100: 80, 20, 250
Table 2, Basic cabling channel parameters Acronym IL
PSACRF (= PSFEXT - IL)
PSANEXT
Formula
-20log((10^(A1-B1(log(f)))/-20)+E1(10^(C1D1(log(f/F1)))/-20)), 1≤f<F1; … -20log((10^(An-Bn(log(f)))/-20)+En(10^(CnDn(log(f/Fn-1)))/-20)), Fn-1≤f<Fn; … A1-B1(log(f)), 1≤f<C1; A2-B2(log(f)), C1≤f<C2
PSAACRF (= PSFEXT - IL)
A1-B1(log(f)), 1≤f<C1; A2-B2(log(f)), C1≤f<C2
CAN
TCL
A1-B1(log(f)), 1≤f<C1; A2-B2(log(f)), C1≤f<C2
CAF
n/s
n/s
PSCMCL
70, 10
75, 10
TCTL
A-B(log(f))
CAN
A-B(log(f))
CAF
A-B(log(f))
PSCMCL
A-B(log(f))
Table 4, Basic cabling channel parameters
NOTE: while PSACRF is used to specify cabling channel limits, PSFEXT is used in the channel noise model, likewise for PSAACRF and PSAFEXT. PSFEXT and PSAFEXT are derived from the measured parameters, PSACRF and PSAACRF, respectively. NOTE: Propagation delay and delay skew parameters are not included in SNR calculations
Parameter
Formula Coefficients
Acronym
CAT6A EA
CAT7A FA
f= MHz
500
1000
IL
1.82, 0.0091, 0.25, 0.02
1.8, 0.005, 0.25, 0.02
RL
19, 0, 10; 24, 5, 40; 32, 10, 398.1 6, 0, 500
19, 0, 10; 24, 5, 40; 32, 10, 251.2 8, 0, 631 36, 10, 1000
PSNEXT
72.3, 15, 90, 20, 2, 500
102.4, 15, 113.3, 20, 2, 1000
PSACRF (= PSFEXT - IL)
64.8, 20, 80.1, 20, 4, 500
92.3, 20, 100.9, 20, 4, 1000
PSANEXT
80, 10, 100; 90, 15, 500
95, 10, 100; 105, 15, 500
PSAACRF (= PSFEXT - IL)
77, 20, 500
92, 20, 1000
TCL
53, 15, 30; 60.3, 20, 500
50, 17, 1000
TCTL
30, 20, 30
34.6, 20, 1000
CAN
40, 0, 100: 80, 20, 500
40, 0, 100: 80, 20, 100
CAF
n/s
n/s
PSCMCL
80, 10
90, 10
NOTE: The normal figures are given with positive values, which represents a magnitude of loss. NOTE: Most parameters have upper bounds and some have lower bounds, which are specified for measurement limitations, however these are not applied to these parameters in SNR calculations
NOTE: Parameters are extended beyond their upper frequency specification in SNR calculations, using straight-line extrapolation.
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6.1.2 Channel parameters specifications
6. NOTES 6.1 Channel parameters details
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6.1.3 Channel parameters as specified: The following three examples are continued from 3.2.1.3.
6.1.4 Channel parameters as according to typical cancelatio
The following three examples are con
Figure 8, Class-D/CAT5e channel IL (signal) and RL & crosstalk (noise) parameters contributing to SNR.
Figure 11, Class-D/CAT5e cancelation: reduced RL, 55d PSFEXT, 25
Figure 9, Class-E/CAT6 channel IL (signal) and RL & crosstalk (noise) parameters contributing to SNR.
Figure 12, Class-E/CAT6 chann reduced RL, 55dB; PSNEXT, 40
Figure 10, Class-FA/CAT7A channel IL (signal) and RL & crosstalk (noise) parameters contributing to SNR.
Figure 13, Class-FA/CAT7A cancelation: reduced RL, 55d PSFEXT, 25 80 | 65TH IWCS CONFERENCE PAPER
6.1.4 Channel parameters as specified, adjusted 6.1.4 Channel parameters as specified, adjusted according to typical cancelation parameters: according to typical cancelation parameters: The following three examples are continued from section 4.
s are continued from 3.2.1.3.
The following three examples are continued from section 4.
5e channel IL (signal) and RL & 5e channel IL (signal) and RL & ameters contributing to SNR. ameters contributing to SNR.
Figure 11, Class-D/CAT5e channel SNR with Figure 11, Class-D/CAT5e channel SNR with cancelation: reduced RL, 55dB; PSNEXT, 40dB; and cancelation: reduced RL, 55dB; PSNEXT, 40dB; and PSFEXT, 25dB. PSFEXT, 25dB.
6 channel IL (signal) and RL & 6 channel IL (signal) and RL & ameters contributing to SNR. ameters contributing to SNR.
Figure 12, Class-E/CAT6 channel SNR with cancelation: Figure 12, Class-E/CAT6 channel SNR with cancelation: reduced RL, 55dB; PSNEXT, 40dB; and PSFEXT, 25dB. reduced RL, 55dB; PSNEXT, 40dB; and PSFEXT, 25dB.
7A channel IL (signal) and RL & 7A channel IL (signal) and RL & ameters contributing to SNR. ameters contributing to SNR.
able Symposium
TECHNICAL PAPERS
ters as specified: ters as specified: s are continued from 3.2.1.3.
Figure 13, Class-FA/CAT7A channel SNR with Figure 13, Class-F /CAT7A channel SNR with cancelation: reduced ARL, 55dB; PSNEXT, 40dB; and cancelation: reduced RL, 55dB; PSNEXT, 40dB; and PSFEXT, 25dB. PSFEXT, 25dB. OCTOBER 2017 | 81
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Insertion loss IL may be effectively reduced by digital signal processing (DSP), which is realized as coding gain, e.g. forward error correction (FEC).
6.2 Channel capacity and margin basics [10] Information capacity of a channel gives the maximum value, in bits-per-second (b/s), for transmitting data through the channel.
Insertion loss (IL) may be reduced by analog signal processing, which is implemented by amplification, e.g. pre-emphasis or equalization.
Cabling channel signal-to-noise-ratio (SNR) Channel capacity is determined according to the Shannon-Hartley capacity theorem, which essentially states that capacity is proportional to the “area under the curve” of the SNR over the particular bandwidth, (i.e. integrated SNR power over BW).
Return loss Return loss is reduced by echo cancellation; digital and analog techniques may be used.
Shannon capacity
Internal crosstalk
Shannon Capacity is an expression of SNR and bandwidth. Capacity is proportional to the integrated SNR (dB) over the bandwidth utilized. The Shannon capacity is the maximum information capacity available within a particular channel. The typical expression of the Shannon capacity of a channel is given in equation (4).
Internal crosstalk is reduced by crosstalk cancellation. The DSP techniques are similar to those used for echo cancelation. Crosstalk reduction can be very effective, with more than 50dB cancellation being possible. Alien-crosstalk (External crosstalk) Alien-crosstalk is not normally cancelled. A practical transceiver cannot significantly cancel interfering signals from other channels.
(1) Where, CSH = channel Shannon capacity S(f) is simply the IL scaled by the TX launch power, and N(f) is simply the band-limited white self-noise BW is the signal bandwidth in Hz. For simplicity use flat (white) TX power spectrum
The power-sum accumulation of the six basic noise parameters contributing to the total noise, used for a particular SNR channel model, have the cancellation “implementation margins” applied to the standard limits accordingly: 1)
The channel Shannon capacity must be significantly greater than the minimum capacity required to support a particular application. For example, to support 10GBASE-T the supporting channel capacity must be significantly greater than 10 Gb/s.
RL (Echo), cancellation 55 dB
2)
NEXT, cancellation 40 dB
3)
FEXT, cancellation 25 dB
4)
ANEXT, cancellation 0 dB
Margin to capacity over frequency
5)
AFEXT, cancellation 0 dB
Margin to capacity: channel figure-of-merit
6)
CMCL, cancelation 0 dB
Margin to capacity is the difference in dB between the maximum channel (Shannon) capacity and designated application capacity, e.g. 10 Gb/s.
Additional margin to capacity must be achieved by utilizing analog signal processing, e.g. “equalization”, “pre-emphasis” or other signal amplification techniques, which is practical up to several dB. Additional effective gain, “coding gain”, for assuring maximum bit-error-rate (BER) conformance, is realized from forward error correction (FEC) techniques.
SNR Margin to capacity: From Shannon capacity, min SNR in dB is given by (2) Where,
6.4 Relationship of alien-crosstalk to coupling-attenuation
(3)
The individual mode conversion parameters
(4)
Table 5, Channel transfer function matrix mode conversion parameters
Where, C = channel Shannon capacity C’ = XX Gb/s minimum required capacity
REVERSE/FORWARD
TRANSMISSION
CROSSTALK
6.3 Channel capacity improvements from digital signal processing [5]
INTERNAL
RL/IL
NEXT/FEXT
EXTERNAL
TCL/TCTL (CAN/CAF)
ANEXT/AFEXT
Transmission losses and crosstalk are reduced by analog and digital signal processing techniques. Echo cancelation for RL and Crosstalk cancelation for NEXT and FEXT are the primary correction techniques utilized for enhancing channel capacity.
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For U/UTP, twisted-pair cabling, CAN and TCL are equivalent, and CAF and TCTL are equivalent.
[8] TIA-568-C.2 (August 2009) Commercial Building Telecommunications Cabling Standard Part 2: Balanced Twisted- Pair Cabling Components, Telecommunications Industry Association (TIA), www.tiaonline.org
CA and alien-crosstalk use similar specification levels at high frequency. They are proportional and have been shown to be correlated. Where +10dB CA relates to about +10dB aliencrosstalk.
[9] TIA-568-C.2 Addendum 1 (August 2016) Balanced TwistedPair Telecommunications Cabling and Components Standard, Addendum 1: Specifications for 100Ί Category 8 Cabling
7. Acknowledgments Special thanks to the IWCS organization and sponsors for continuously maintaining this forum for twisted-pair data network cabling systems development, during 5 media generations over 25 years.
[10] Twisted-Pair Cabling Channel Capacity Modeling, David C. Hess, IWCS 2014
9. Author
8. References
David Hess, CORD DATA, 1222 Dauphin Avenue, Wyomissing, PA 19610, USA, davecarlhess@outlook.com, +1 610 698 4790
[1] IEEE Std 802.3™-2012 (Revision of IEEE Std 802.3-2008) IEEE Standard for Ethernet
David Hess, currently working as an independent consultant facilitating international standards for connectivity technology, has worked for more than 35 years in both fields of electronic and photonic data communication connectivity, participates on committees for data communications standards and physical interface standards, ISO/IEC/JTC1, IEC, INCITS, IEEE, ITU, ANSI, TIA and EIA; notably, TIA TR42, Cabling systems, since 1989; IEC SC46C, Balanced cables, since 1991; ISO/IEC/JTC1/SC25, Cabling systems, since 1993; IEC SC48B, Electronic Connectors, since 1996; TIA TR30 for ANSI/EIA-RS232 and RS-485, since 1978; IEEE, INCITS, and ITU, since 1985. He has been project leader for 10 international standards. He received the IEC 1906 award for technical contributions, in 2011 and 2014. He holds a B.S. degree in Mathematics from Pennsylvania State University and is a member of IEEE.
[2] IEEE 802.3bq draft part 113, 25G/40GBASE-T, standard task force document draft 3.3, 2016-07 [3] IEEE 802.3bz draft part 126, 2.5G/5GBASE-T, standard task force document draft 3.2, 2016-07 [4] ISO/IEC ISO/ 11801-1 ed. 1.0, DIS, 2016-07, Information technology - Generic cabling for customer premises, ISO/IEC JTC 1/SC 25 [5] ISO/IEC/TR 11801-9901 ed. 1.0, 2014-10, Information technology - Generic cabling for customer premises - Part 9901: Guidance for balanced cabling in support of at least 40 Gbit/s data transmission, ISO/IEC JTC 1/SC 25 [6] ISO/IEC/TR 11801-9904 ed. 1.0, DTR 2016-05, Information technology - Generic cabling for customer premises - Part 9904: Assessment and mitigation of installed balanced cabling channels to support 2,5GBASE-T and 5GBASE-T, ISO/IEC JTC 1/SC 25 [7] ISO/IEC/TR 11801-9905 ed. 1.0, DTR 2016-06, Information technology - Generic cabling for customer premises - Part
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9905: Guidelines for the use of installed cabling to support 25GBASE-T application, ISO/IEC JTC 1/SC 25
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Ajex & Turner Wire Technology........................14
Guill Tool & Engineering Co .............................62
Amacoil Inc .............................................. Cover 3
Howar Equipment Inc ........................................12
Anbao Wire & Mesh Co Ltd ..............................34
Howar Equipment Inc/Metavan ........................62
Bartell Machinery Systems LLC .......................37
Huestis Industrial ..............................................24
Cable Components Group ..................................5
Inosym Ltd ...................................................21, 38
Carris Reels Inc ....................................... Cover 4
KEIR Manufacturing Inc ....................................85
Cemanco ............................................................69
Lamnea Bruk AB ................................................49
DeWal ..................................................................16
Locton Limited ...................................................85
Electric Cable Compounds Inc.........................26
Messe Dusseldorf North America ....................43
Electron Beam Technologies Inc .....................34
Metavan/Howar Equipment Inc ........................62
Esteves Group USA...........................................51
Mexichem Specialty Compounds Inc .... Cover 2
George Evans Corp ...........................................23
Morgan-Koch Corp ............................................61
Fenn LLC ............................................................15
Oden Technologies ...........................................29
Flymca & Flyro ...................................................53
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Process Sheaves LLC .......................................22
Ulbrich Stainless Steels Inc........................41, 63
Proton Products International Ltd ...................57
Upcast OY ............................................................9
Queins Machines GmbH ...................................17
Vandor Corporation ...........................................35
Rainbow Rubber & Plastics Inc..........................2
Wire & Plastic Machinery Corp ........................13
Redstone Machinery LLC .................................18
Wyrepak Industries .....................................31, 36
REELEX Packaging Solutions Inc....................25
Zumbach Electronics Corp ...............................33
Sandvik Hyperion ..............................................65 Sanxin Wire Die Inc ...........................................27
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