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Power cables with shielding are available in various types based on their construction, application, and voltage requirements. These cables are often used in many industrial, commercial, and residential settings.
Low Voltage Power Cables
These carry voltage levels up to 1,000 V. They have a thin insulating layer. Low-voltage cables run in electrical distribution systems, lighting, heating, and powering household appliances. They are flexible. That is why they are suitable for use in buildings, offices, and other facilities.
Medium Voltage Power Cables
These handle voltage levels between 1 kV and 35 kV. They have a good shield for insulation. MV cables are used in industrial plants, utility systems, and commercial facilities to distribute power over longer distances. They are durable and provide reliable transmission in areas that require more than just low-voltage power.
High Voltage Power Cables
High-voltage cables are used for transmission with voltage levels above 35 kV. These cables are massive and have multiple shield layers. They are mainly used in utility power grids, long-distance transmission, and other applications that require dealing with large amounts of electrical energy.
Armored Power Cables
These have a steel or aluminum armor layer on the outside. The armor protects the cable from mechanical damage. These cables are mainly used in hazardous environments. Such places include construction sites, mines, or industrial settings where there is a risk of heavy impact, abrasion, or crushing.
Flame Retardant Power Cables
These cables are designed not to spread flames. They are fitted with an insulating layer that will not allow fire to spread. FR cables carry electric current in areas where fire safety considers an important factor. These include tall buildings, offshore oil rigs, and public transport systems.
Submarine Power Cables
They are specifically designed for power transmission across water bodies. They have shielding and insulation layers that protect them from pressure, moisture, and sometimes extreme temperatures. Submarine cables are mainly used in offshore energy projects. These include underwater wind farms and oil and gas rigs and connect islands.
Still, a shielded power cable is used in most industrial settings. The cables protect sensitive lines from electromagnetic interference (EMI) or radiofrequency interference (RFI). Industries use these cables for control, signal transmission, and power lines. Shielded cables are vital in manufacturing plants. This is because they ensure that machinery runs efficiently, and there are no disruptions.
Oil and Gas Industry
The oil and gas drilling industry have drilling rigs and other harsh environment work-over equipment. Power cables should withstand pressure, temperature, and exposure to hazardous substances. They have to carry electrolytic current to heavy machinery, pumps, compressors, drills, etc. Shielded cables are durable and reliable. So they are the best for these environments where mechanical damage and extreme conditions are a norm.
Construction and Mining Industry
In construction and mining, armored power cables are used to run heavy equipment, tools, and lighting systems. These cables must have a high current-carrying capacity and mechanical strength to operate safely in extreme environments. Minor electrical hazards in such conditions can lead to major safety risks. So, cable reliability is very important.
Automotive and Aerospace Industry
These industries need lightweight, compact, and highly reliable shielded power cables. They go through rigorous testing for safety and performance. Shielding is especially vital in automobiles. After all, with all the running engines, the signal interference can be a lot. It can be found in any form of power tool or machinery. Shielded cables help ensure that communication and control systems operate reliably in which environment.
Renewable Energy Sector
This sector heavily relies on shielded power cables in wind, solar, and geothermal energy generation systems. Give or take, shielded cables help minimize interference with sensitive instrumentation and control signals. This then ensures the accurate operation of the system. Shielding is also important for submarine power cables used in underwater transmission projects.
Telecommunications and Data Centers
These businesses have high-demand infrastructure, after all. They need shielded power cables to supply power to servers, routers, and other critical equipment. These cables help prevent noise and interference. That ensures the uninterrupted operation of sensitive electronics. Shielded power cables help maintain reliable operations in data centers.
Power cables with shielding have come a long way since their invention in the last century. Countless innovations and improvements have been made to them over the years. And several trends have arisen globally.
Technological Advancements
Over the years, several advancements have been made in cable materials and production techniques. These ensure greater durability and efficiency. There are new insulation and shielding materials that improve the cables' energy transmission capacity.
Increased Demand for Renewable Energy
The renewable energy sector has increased the demand for shielded cables. These cables are crucial for connecting solar panels, wind turbines, and other renewable energy systems to the grid.
Focus on Durability and Safety
Several industries prioritize the use of long-lasting and safe power cables. Their work is often in dangerous situations. What goes into these cables must be fire-resistant, waterproof, and have good mechanical protection. All these features are a priority for industries like construction and mining.
Growth in Electric Vehicle Market
The rise of EVs is increasing the demand for shielded power cables. They power batteries, charging systems, and other in-vehicle electronics. These wires have to be lightweight, flexible, and capable of carrying high electric currents.
Retrofitting and Replacement Demand
Many old infrastructure systems are still in use today. This is especially true for industries and commercial buildings that were built ages ago. Their power cables have to be replaced or retrofitted with newer, more efficient shielded power cables. The need to replace aging infrastructure has led to high demand for durable power cables.
Power cables with shielding are made from several different materials. Each one chosen for its specific properties and advantages. Here is a list of them:
Conductors
The conductor transmits the electric current, after all. Most are made of copper or aluminum. Copper has high conductivity, flexibility, and is corrosion resistant. It then becomes the better material to use for power cables. Aluminum costs less and is much lighter. So, it is a more affordable alternative. It is often used when one needs to construct much larger cables.
Insulation
The insulation layer around the conductor provides electrical safety. PVC is durable, cost-effective, and resistant to chemicals. So, it is commonly used for low-voltage cables. Polyethylene has a higher temperature threshold. It is often used in environments that get hotter than usual. Lastly, thermoset rubber is extremely durable and flexible.
Shielding
The shielding layer protects against electromagnetic interference (EMI) and radio frequency interference (RFI). This then ensures signal integrity. There are mostly two types of shielding. They are the foil and braided types. Foil shielding has thin metal layers that are flexible and lightweight. Braided shielding, on the other hand, uses interwoven metal wires for better durability.
Armor
Some cables have armor for mechanical protection. Steel wire armor (SWA) provides robust protection in harsh environments, while aluminum wire armor (AWA) is lighter and more corrosion-resistant.
Jacketing
The outer layer also known as the jacket protects all the inner layers from environmental damage. PVC is cost-effective and has durable applications, while nitrile PVC (NVP) is highly resistant to oils and chemicals.
Several factors should be considered for power cables with shielding to reduce EMI and RFI. These factors should apply especially in industrial contexts where machinery and electronic devices are in constant operation.
Shielding Type
These shielded power cables have two main shielding types. They are foil and braided shielding. The former provides excellent protection and is cost-effective. The latter has better durability for harsh environments.
Jacket Material
A cable's insulating layer protects its conductors and shielding. One should choose materials that can endure chemicals, moisture, and extreme temperatures. They are most likely what a cable will face in its environment.
Conductor Configuration
Single or multi-conductor configurations are how these cables come in. Multi-conductors increase power and signal transmission simultaneously, after all. One should, therefore, consider their specific needs when choosing cables with shielding.
Application
Where one will use the cable highly determines which one to go with. For instance, automotive and aerospace applications require lightweight cables with shielding. Meanwhile, industrial settings need heavy-duty shielded power cables.
Cable Length
Longer cables have more resistance. So, longer cables will cause thicker cables too. One should also factor in how much EM interference they will ultimately have to deal with. The greater the interference, the longer the cable distance.
Shielded power cables are an essential item in most industries. People especially value their ability to minimize electromagnetic interference (EMI). Manufacturing, aerospace, telecommunications, and medical industries commonly use these cables. They all have machinery and equipment that are extremely sensitive to electrical noise.
Yes, shielded power cables can go outdoors. But one has to ensure the external environmental conditions first before going for outdoor shielded power cables. Temperature, humidity, or exposure to chemicals are examples of external conditions that power cables with shielding can withstand.
Shielded power cables are pricier than unshielded ones due to their extra materials and manufacturing processes. However, their increased cost is justified in industries with high EMI exposure. That is because they help prevent costly downtime and equipment damage.
The maintenance of these cables is not that hard. Routine visual inspections for damage or wear exposure to harsh environments will do the trick. People also perform periodic testing to check for electrical continuity and shielding effectiveness.