Copper Flexible Ropes with Overall Braiding
Yeshwant Wires is a trusted Copper Flexible Ropes with Overall Braiding manufacturer in India, offering premium-quality flexible conductors engineered for high electrical performance, durability, and protection. These specialized ropes are constructed from multiple fine strands of electrolytic-grade copper and covered with an overall copper braid that enhances mechanical strength, electrical shielding, and flexibility.
Designed for critical power and grounding systems, these ropes deliver exceptional conductivity, flexibility, EMI shielding, and durability. They comply with IS, IEC, and ASTM standards and are ideal for switchgear, transformers, welding equipment, generators, and power distribution systems in dynamic or high-vibration environments.
Description
Copper Flexible Ropes with Overall Braiding are made by combining multiple fine copper strands into a highly flexible conductor, followed by a tight outer layer of braided copper wire. This braided layer acts as a mechanical and electrical shield, ensuring superior flexibility, strength, and EMI resistance. They are ideal for connections requiring frequent movement, vibration resistance, or high current flow with minimum voltage drop.
These ropes are extensively used in switchgear, transformers, welding equipment, generators, power distribution systems, heavy industrial machinery, battery banks, earthing systems, railways, automotive, and marine applications where both flexibility and mechanical shielding are critical for reliable power transmission and signal integrity.
Key Features & Advantages
- Excellent Conductivity: Made from 99.99% pure electrolytic copper wire.
- Enhanced Mechanical Protection: Overall braiding safeguards the conductor from friction and damage.
- Superior Flexibility: Suitable for movable or vibrating connections.
- Electromagnetic Shielding: Reduces electrical interference and improves signal performance.
- Corrosion Resistant: Available in both bare and tinned copper finishes.
- Long Service Life: Designed for continuous current-carrying operations under mechanical stress.
- Customizable: Available in various lengths, sizes, and constructions per requirement.
Technical Specifications
| Property | Specification | Significance |
|---|---|---|
| Conductor Material | High-Conductivity Electrolytic Copper (Bare or Tinned) | Copper ensures maximum current capacity. Tinned copper is often chosen for corrosion resistance, vital for longevity. |
| Voltage Grade | Typically Up to 1.1 kV (Low Voltage) | The voltage rating is based on the inner insulation (if present). This construction is primarily used for high-current, low-voltage connections. |
| Operating Temperature | -40°C to +150°C (Insulation Dependent) | The high rating reflects the robust copper conductor and the use of high-temperature insulation materials (like silicone or EPR) often required in power electronics or motor connections. |
| Conductor Construction | Ultra-Fine Strands (Class 5 or Class 6) twisted into Ropes | Provides extreme flexibility and resistance to fatigue, making it suitable for dynamic or constantly moving applications like robot arms or welding leads. |
| Overall Braiding Material | Bare or Tinned Copper Wire (Woven) | Defining Feature. The copper braid acts as a metallic reinforcement for mechanical strength and can serve as an extra-low resistance earth (grounding) path or an electromagnetic shield. |
| Insulation/Sheath | Silicone, Rubber (EPR/TPE), or PVC (Inner Layer, under the braid) | The inner layer provides dielectric isolation. Silicone or Rubber is often used for maximum flexibility, chemical resistance, and wide temperature range. |
| Key Function | Dynamic High-Current Connections, High-Flex Grounding Jumper, EMI Shielding | Used in environments requiring both high current capability and continuous movement, such as machine tool connections, rail rolling stock, and welding equipment. |
| Standards | IEC 60228 Class 6 (for conductor), relevant industry standards for insulation/braiding. | Compliance with Class 6 confirms the conductor meets the highest flexibility requirements. |
Applications
Copper Flexible Ropes with Overall Braiding are used in high-performance electrical systems where both flexibility and mechanical shielding are required. Common applications include:
- Switchgear and Control Panels
- Transformers and Busbar Systems
- Battery Banks and Power Distribution Networks
- Welding Equipment and Generators
- Railways, Automotive, and Marine Applications
- Earthing and Bonding Systems
Manufacturing & Quality Assurance
At Yeshwant Wires, every copper rope is produced using state-of-the-art braiding and stranding machines for precision and reliability. Ropes undergo rigorous testing for tensile strength, flexibility, resistance, conductivity, and braid coverage under ISO certified quality systems.
Why Choose Yeshwant Wires?
- Leading Copper Flexible Ropes with Overall Braiding Manufacturer in India.
- ISO-certified production facilities with modern testing equipment.
- Custom-built designs and constructions for industrial and power applications.
- Trusted supplier to switchgear, transformer, and renewable energy sectors.
- Prompt delivery, consistent quality, and competitive pricing.
Industries We Serve
We supply Copper Flexible Ropes with Overall Braiding to diverse industries such as power generation, electrical switchgear, automotive, renewable energy, and heavy equipment manufacturing. Our solutions are tailored for high performance, innovation, reliability, and precision-engineered conductivity in demanding applications.
