Contents №4–2015

Analyses and Forecasts

G.I. Meshchanov, Dr. Sc. (Engineering), President
E.I. Uvarov, Analyst-Advisor to General Director
Electrocable Association

Contact: elektrokabel@rosmail.ru 

Performance results of Electrocable Association companies for the first half year and 8 months of 2015


Current state of the cable industry in Russia and other CIS countries is analyzed. Challenges faced by the industry as a result of the economic downturn, especially in Russia, are reviewed. Cable products production dynamics by different areas of application are also reviewed as well as how these dynamics are affected by performance of other sectors of the economy and how cable product imports are changing. Estimates are provided in terms of the total production levels of cable products for the year 2015.

Key words

Macroeconomic indicators; cable production in Russia and the CIS countries; sector use of cables and wires.

Science and Technologies

A.A. Kamenev, Cand. Sc. (Chemistry), Senior Researcher, ZAO “SuperOks”; 
A.A. Kryuchkov, Cand. Sc. (Chemistry), Leading Researcher, 
M.A. Nikolaeva, Engineer, 
M.Yu. Shuvalov., Dr. Sc. (Engineering), Director of Energy Cable and Wire Division; 

Contact: a.kryuchkov@vniikp.ru

Investigation of long-term mechanical strength of composite cable materials

The results of investigations of long-term mechanical strength of four halogen-free flame retardant polymer compounds are presented. The voltage dependences of durability for all test materials in semi-logarithmic coordinates are linear within a limited voltage range. The influence of temperature on the voltage dependence of durability is shown. The authors see a certain similarity between long-term mechanical strength and long-term electric strength of polymer compounds. The electron scanning microscopy method was used to investigate the surface structure of the specimens before and after the long-term mechanical strength tests. Based on the obtained results the authors arrive at the conclusion that the microcracks in the loaded specimens originate at the polymer-filler phase boundary. Data on mechanical stress relieving in specimens of one of the tested materials at room temperature are given.

Key words

Long-term mechanical strength; composite polymer materials; durability; microcracks; electron microscopy.

Yu. A. Zelenetsky, Head of Scientific and Technical Center of OAO “Zavod “Microprovod”; 
A.S. Kobelev, Cand. Sc. (Engineering), Head of Computation-Theoretical Department of PAO “Scientific Research and Development Institute of Electric Machine Industry”

Contact: zelenezky@mikroprovod.ru  

Improvement of energy efficiency of induction motors by application of enameled wires manufactured using state-of-the-art technology

The paper discusses potential improvement of energy efficiency of induction motors by way of reducing losses in the stator winding due to the use of advanced enameled wire constructions with reduced insulation layer thickness. It is shown that for most applications the insulation breakdown voltage value is redundant. Decrease of the breakdown voltage down to the admissible threshold due to the reduction of the insulation coating thickness allows to increase the volume of pure copper in the groove and therefore to switch over to producing electric motors of a higher energy efficiency class with minimal additional expenditure. Amendment to the induction motor design technique is offered. The main point of this amendment is the following: optimal thickness of enameled wire insulation coating should be selected individually for each designed motor dimension-type with allowable reliability tolerances taken into account.

Key words

Energy efficiency; induction motors; enameled wires

M.A. Boev, Dr. Sc. (Engineering), Professor of National Research University (MEI); 
Maung Aye, post-graduate student of National Research University (MEI)


Short-term mechanical strength of aerial optical cables


Tensile test results of self-supporting aerial optical cables of ОПЦ, ОПД, ОСЦ, ОСД types are presented. The applied load, optical fiber attenuation and cable elongation were monitored in the course of testing. The tests were carried out using РРК-ЕК2 type stretching and crushing test unit with the stretching force increased up to 14 kN.
Optical fiber attenuation dependences on cable elongation and cable elongation dependences on stretching force were obtained. Linear equations are offered for mathematical description of the processes occurring under the exposure to each of the discussed factors.

Key words

Attenuation; linear approximation; mechanical strength; optical cables; stretching force; elongation.

I.B. Peshkov, Dr. Sc. (Engineering), Professor, President of International Intercable Association


Innovative materials in cable production


The author gives a brief description of some new materials that have already been used or will find use in the development and production of cable and wire in the nearest future. These include: multicore fiber lightguides, hollow-core fiber lightguides, halogen-free polyolefin compositions, fluoropolymers, polyolefin-based cross-linkable compounds, polyetheretherketone, thermoplastic polyimide, polyethylene fiber and yarn with super-high molecular mass, new waterblocking materials, and new drawing lubricant-coolants. Information concerning specific technologies of cable and wire production is given.

Key words

Multicore fiber lightguides; hollow-core fiber lightguides; halogen-free polyolefin compositions; fluoropolymers; polyolefin-based cross-linkable compounds; polyetheretherketone; thermoplastic polyimide; polyethylene fiber and yarn with super-high molecular mass; waterblocking materials; drawing lubricant-coolants.

G. Prunk, Chief Executive of SIKORA AG


Subsea and EHV cables require a challenging purity degree of XLPE-material


This paper outlines the reason for the need of a high purity degree of XLPE material to be used for the insulation of subsea and EHV cables. Furthermore, there will be technological solutions introduced for purity assurance of XLPE pellets that are integrated at specific production stages.

Key words

XLPE compound, subsea cables, EHV cables, extrusion line, the control of melt temperature, melt purity control, purity control pellets.


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