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The following discussion must bring some light into the darkness of the cable myth with the accomplishment of the new SILVER LINE cable series.
With the start of each new and further development we have an intellectual engagement with questions “why and how”. The question “why” is usually quickly resolved, such as the availability of a new and better economical product.
An answer to the question “how” gives us a greater demand towards the development and manufacturing. The answer to that question is to bring-in new ideas for more economic manufacturing methods and solutions and to implement and produce marketable products, which include areas of planning, production and logistic distribution, which require more exigencies.
But now back to our topic, the re-make of the SILVER LINE cable series.
The starting point of each cable production is the selection of conductor materials, the primary and secondary insulation and the outer mantle design. The selection of the conductor material is influenced primarily by economic issues. The range of diversity and possibilities of normal electrolytic copper power cable in the applications used in our household towards more sophisticated applications in the industry, that use special low-oxygen copper with a purity of 99.9% to copper / silver compound materials and pure silver.
The receipt of the copper conductor material.
Our decision to use a low-oxygen copper OFHC from an economic aspect for our SILVER LINE cable series guarantees us the best possible electrical values.
The conductor material combines the best conductivity and cost/performance ratio.
The conductive material is delivered to our plant as solid copper or stranded copper wire.
One of our main concerns is the quality of transmission for our SILVER LINE cable and the choice of the primary insulation and the insulation, which is around the individual conductors.
The primary insulation determines the main electrical characteristics of our cable.
In the area of electro-acoustic transmission, signals are the values of cable capacitance, the inductance and the line attenuation and insulation resistance of the utmost importance.
The price also determines the use of different applications. There is a range of simple PVC (polyvinyl chloride) with minimal electrical properties of PE (polyethylene), PETP (Polyestertheraphtalat) to most-insulation as ETFE (Tefzel) and Teflon PTFE. The secondary insulations for sheaths and outer sheathings are in their electrical properties for the transmission quality is no longer crucial. Here is flexibility-, mechanical strength, surface quality and cable design playing an essential role.
As a primary insulation in our SILVER LINE cable series, the power cable for N1 STC and the speaker cable LS2 SILVER a special high-pressure polyethylene (HDPE-2Y) are used. In the small-signal cable KS1 SILVER we have decided to use for better quality TEFZEL (from the family of Teflon).
On top the stranded cable cores, in the power cord and the small Silver N1 STC signal cable K1 SILVER is the composite shielding used.
Furthermore sheaths are extruded from a special thermoplastic and apply as a textile outer jacket, black with silver thread woven filament fabric.
Rohstoffsilos für das Granulat./Weiterverarbeitung des Granulats im Fertigunsprozess.
All raw materials in granular form are delivered and stored in large silos from the chemical industry such as Bayer Leverkusen and DuPont.
The granular products are added into the production process in predetermined quantities in the respective processing machines (extruders).
Head Shelter in extruder.
After the conductor and insulation materials were established, the geometric structure and the outer mantle design were improved and the production of our cable series SILVER LINE was started.
This began with the extrusion (sheath) of the individual conductors. These individual conductors, with each specific insulation material at high temperatures in the extruder were sheathed. In the manufacturing process the section thickness of the insulation mantle and outer mantle strength were precisely observed. During the production process an insulation test with a high voltage of 5000V rms was conducted.
After completion of the single wire, the stranding head started on the design, provided for each cable element.
With our power cord N1 STC and the speaker cable L2 Silver the individual conductors were twisted into pairs.
Stranding of the wires.
Pair’s cabling of the respective supply and return conductor were optimized with a lead inductance and capacity.
After completion of the individual elements the final cabling core with the basket-closer.
The choice of the individual stroke lengths and the stranding is (opposite direction of impact - "cable shielding") is very important one for the transmission quality and the other for the reproducibility of the cable core.
View inside production.
The wire tie applies subsequent to the stranding. For the shields of the power cord N1 STC SILVER and the NF-cable KS1 SILVER., for both cables a "network shield" (STC) with a HF density is 100% was used. This association consists of an alum-Mylar foil shielding and a copper braid or a copper thread. This "STC" shielding ensures a low static and electrical interference.
At the same time we obtain the best value for effective shielding.
The last steps in the process of our SILVER LINE series were the extrusion of the inner coil boiler of the braiding machine, called the coat extruder. The mantle braiding of the LS2 speaker cable sheath gowns and the application of textile filament braids. The creation of the sheaths is carried out in the jacket extruder.
Tumbling of shielded cable.
The Mantelextruder. / shell lichens of the speaker cable LS2.
The filament network is applied to specific wire braiding machines.
Herewith was the manufacturing process of our cable SILVER LINE series finished.
Now we were able to start with checking the different processes, presentation and packaging.
Examination of KabelzentrizitÃ¤t. / Mr WÃ¤chter in field testing.
First we started with a high-voltage test. The different parts were tested against each other, respectively screened. Subsequently, the individual parameters of the Silver Line cables such as capacitance, inductance, conductor and insulation of the conductors were inspected and recorded in measurement and controlling reports.
Look at the Department cable assembly.
After successful completion of all the measurement and controlling, the SILVER LINE cables were rewound in various lengths to specific coils and/or rings.
For our customers the specific coils and/or rings will be labelled and packaged.
In the assembly section of the cable series “SILVER LINE”, the cables will be cut with a predetermined length and foreseen with appropriate connectors and terminals and afterwards packed for sale.
At this stage we would like to thank all employees of the cable factory for their support and commitment for the production of our SILVER LINE cable series.
Special thanks go also to the production line, which lives from the production of the small SILVER LINE, GOLD- and PLATIN LINE with a length of more than 10,000 meters.