Attenuation-Based Cable Design for High-Quality Manufacturing

Attenuation-Based Cable Design for High-Quality Manufacturing

Leonid Burstein (Kinneret Academic College, Zemah, Israel) and Asher Bohbot (Teldor Cables and Systems Ltd., Ein-Dor, Israel)
DOI: 10.4018/IJMMME.2017040104
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Abstract

The original design model for defining the attenuation of manufactured cables was derived and fitted to experimental data. The model relationship connects attenuation with some parameters of cable design and testing: copper wire, aluminum, and insulation thicknesses, cable impedance, test frequency, and lay length. Defined expression was used for Monte-Carlo simulation of the cable attenuation prediction. With developed MATLAB program, a special graphical user interface was created. After assigning the desired parameters, this interface generates a plot with distribution of the attenuation values and required attenuation limit, and outputs defined mean attenuation, its 98% error, and numbers of values that get in and out of the limiting value. Data of calculations were verified by experiments and reveal good concurrence with the actual data. The realized fitting and simulation procedure, together with developed programs and created interface can be used as compact tool for designing cables with optimal parameters.
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2. Background And Fitting The Data

The cable and test parameters that were assigned to search for an unifying relation are shown in Figure 1.

Figure 1.

Cable (a) and test (b) parameters selected to the relationship search

The attenuation was selected as the main parameter that should be kept and should be related with other design and test parameters. The general searching dependence reads:

(1) where dcu is the copper wire diameter, mm; dins diameter of the insulator, mm; δAl is the aluminum thickness, μm; I – impedance value required in the cable testing, Ohm ; F – the frequency assigned for the cable test, MHz, ; p – cable lay length, mm; A – attenuation, dB per 100 m of the cable.

The data that connects parameters in Equation (1) were assembled in production line of Teldor Cables and System Ltd. (Attachment 1) for cables designed from four individually foil-shielded twisted pairs with tinned copper drain conductor, and overall braid-shielded and jacketed.

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