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Table of Contents
How do you cut a semi-rigid cord?
Cutting semi-rigid usually involves a saw-type cut. A saw-type cut is preferred because the next step in processing the coax involves dressing the ends for fittings.
Why are coax cables so stiff?
The nature of Coaxial cables is that they are all stiff. The intention is to maintain the spacing between the core and the screen so the permeability stays the the same. This means the geometry of a cable should stay the same along it’s entire length.
How to Process & Fabricate Coax Cable
The nature of coax cables is that they are all stiff. The intention is to keep the distance between the core and the screen so the permeability stays the same. This means that the geometry of a cable should remain the same throughout its length.
Those who bend or have been bent are no longer perfect. For most applications, this perfection may be desirable, but it is not required.
In a production test environment, the length of the cable (connection instruments) is usually determined by where and how the equipment is tested.
So the advice is either to give the devices (to be connected) plenty of slack so everything can “float” in a position where nothing is too taxing, or to use the right length cables for the task.
The OP’s task of finding flexible cables will be as difficult as user6972 said and would be a waste of time unless absolutely necessary.
Is coaxial cable is rigid or flexible?
Coax Type and Electrical Specifications
Generally, a silver-plated copper shielding braid over the insulator provides a high level of flexibility but shielding is not continuous due to the air gaps between the stranded braid.
How to Process & Fabricate Coax Cable
Since the advent of the RG numbering system, manufacturers have continued to advance cable technology through research and development. This was necessary to keep up with new applications and includes improvements in both materials and manufacturing processes. A number of coaxial cables have emerged with extended operational capabilities, allowing for additional system design capabilities.
Coaxial type and electrical specifications
Coax Description Outside Diameter (inches) Dielectric Material Center Conductor Material Shield Material dB/100 ft @ 400 MHz @ 10 GHz RG-58C .195 PE Ag/Cu Ag/Cu Braid 14 RG-119 .465 ST Ag/Cu Ag/Cu Braid 3.8 RG -120 0.523 ST Ag/Cu Ag/Cu braid 3.8 RG-122 0.16 PE Ag/Cu Ag/Cu braid 18 RG-142/A/B 0.195 ST Ag/Cu Ag/Cu braid 9 RG -177 0.895 PE Ag/ Cu Ag/Cu braid 2.8 RG-178/A/B 0.072 PTFE Ag/Cu Ag/Cu braid 29 RG-211/A 0.73 ST Ag/Cu Ag/Cu braid 2.3 RG-212 0.332 PE Ag/Cu Ag/Cu braid 6.5 RG-213 0.405 PE Ag/Cu Ag/Cu braid 5.5 RG-214 0.425 PE Ag/Cu Ag/Cu double braid 5.5 RG-215 0.463 PE Ag/Cu Ag/Cu braid 5.5 RG-217 0.545 PE Ag/Cu Ag/Cu braid 4.3 RG-218 0.87 PE Ag/Cu Ag/Cu braid 2.5 RG-219 0.928 PE Ag/Cu Ag/Cu braid 2.5 RG-223 0.211 PE Ag/Cu Ag/Cu double braid 8.8 RG-303 0.17 PTFE Ag/Cu Ag/Cu braid 9 RG-304 0.28 PTFE Ag/Cu Ag/Cu Braid 6 RG-316 0.102 PTFE Ag/Cu Ag/Cu Braid 20 RG-393 0.39 PTFE Ag/Cu Ag/Cu Braid 5 RG-400 0.195 PTFE Ag/Cu Ag /Cu braid 9.6 RG-401 semi-rigid 0.25 PTFE Ag/Cu Cu full jacket 33 RG-402 malleable 0.141 PTFE Ag/Cu Sn/Cu braid 50 RG-402 semi-rigid 0.141 PTFE Ag/Cu Cu full jacket 41 RG-403 0.116 PTFE Ag/Cu/ Ag/Cu braid 29 RG-405 malleable 0.086 PTFE Ag/Cu Sn/Cu braid 82 RG-405 semi-rigid 0.086 PTFE Ag/Cu Cu full jacket 65
Diagram of coaxial cable types
Flexible coax
Having originally set the performance standard, Flex was the number one choice for military and aerospace applications. This type of coaxial cable offers lower electrical performance compared to semi-rigid and malleable cables, but is more cost-effective. A flexible cable uses either a stranded center conductor when repeated bending is required, or a solid conductor when lower loss is required.
In general, a silver-plated copper braided shield over the insulator provides a high degree of flexibility, but the shielding is not continuous due to the air gaps between the stranded braids. Shielding can be further degraded if flexing of the assembly occurs, thereby increasing the size of the air gaps. This can be overcome by specifying a second or third layer of shielding, but then flexibility is sacrificed.
Semi-rigid coaxial cable
Utilizing a solid copper or aluminum outer shield, the semi-rigid cable offers superior shielding compared to a woven braid. This is particularly evident when higher operating frequencies are required. While this coaxial cable offers higher shielding performance, it is also less flexible and therefore requires fixing to achieve complex routing arcs.
Malleable coaxial cable
Constructed from a tin-filled copper braided outer conductor, the malleable cable has performance characteristics similar to semi-rigid cables, but offers the flexibility to be shaped and reshaped without affecting the coaxial cable. Being hand formable, cost savings are realized as no fixing is required where slip sheets are required.
What is rigid coaxial cable?
Rigid coaxial cable, sometimes called rigid line, consists of two concentrically mounted copper tubes that are supported at fixed intervals across the length of the cable using PTFE supports or disk insulators.
How to Process & Fabricate Coax Cable
Coaxial cable is a form of signal transmission cable used to carry electrical signals between devices, systems, or components. While traditional electrical cables consist of one or more wires through which an electric current flows (a flow of electrons), coaxial cables are used to transmit radio frequency (RF) signals in the form of a transverse electromagnetic wave. Coaxial cable design consists of an inner conductor surrounded by a dielectric layer, which is then encased in a cylindrical sandwich containing additional layers of shielding as well as an outer protective jacket to prevent damage to signal-carrying components during installation or by environmental stresses . Commonly used as transmission lines, coaxial cable can carry high-frequency signals with low losses.
Common types of coaxial cable include:
Hardline coaxial cable
Flexible coaxial cable
Semi-rigid coaxial cable
Malleable coaxial cable
Rigid coaxial cable
Twin axial cable
triaxial cable
The terms coaxial cable and coaxial cable assemblies are often used interchangeably, however some references distinguish the two by defining the assembly to represent the cable material terminated and readily available in standardized lengths. In this context, coaxial cable would represent bulk cable sold in spools or spools, say 100 or 500 feet in length, to which cable connectors are attached once the final cable length has been determined.
Types of coaxial cables
The following sections provide a brief description of each coaxial cable type.
Hardline coaxial cable
Hardline coaxial cable uses a center conductor composed of materials such as copper, silver, aluminum, or steel, and this type of cable is typically larger in diameter than other types of coaxial cable. These types of cables can be used in high strength signal transmission. Some forms of fixed line use pressurized nitrogen as an inhibitor to moisture ingress and to prevent arcing.
Flexible coaxial cable
As the name suggests, a flexible coaxial cable can move and bend as needed to fit the configuration and geometry of the application. A typical flexible coaxial cable design uses a metallic inner conductor surrounded by a flexible polymer that acts as a dielectric, with an outer jacket for protection from the environment. When there is a need to increase flexibility, the metal core conductor can be switched to a solid wire stranded design, and a polyethylene (PE) dielectric foam can replace the stiffer dielectric material.
Flexible coaxial cable is the most common type of coaxial cable and is well known to everyone who has used it to connect home video equipment and televisions.
Semi-rigid coaxial cable
Semi-rigid coaxial cables use a solid copper jacket with a PTFE dielectric. The copper jacket generally offers superior shielding effectiveness and the dielectric properties offer improved high frequency performance. Because of its construction, this type of coaxial cable is not intended to be reshaped or bent after the initial forming process has taken place.
Malleable coaxial cable
An alternative to semi-rigid coaxial cable is malleable coaxial cable, also known as conformable coaxial cable. Instead of a rigid copper outer jacket, a flexible metal jacket is used that can be reshaped and formed by hand to meet the desired cable configuration, which requires special tools. Malleable coaxial cable is sometimes used to create the design for cable placement in prototype applications and once stabilized the design is converted to use the semi-rigid coaxial cable.
Rigid coaxial cable
Rigid coaxial cable, sometimes called rigid conduit, consists of two concentrically mounted copper tubes supported at fixed intervals along the length of the cable with PTFE supports or disc insulators. Although referred to as rigid coaxial cable, the term rigid coaxial transmission line is perhaps a more appropriate moniker since cable has traditionally been thought of as being flexible or bendable. Rigid transmission lines are manufactured and sold in flanged straight sections of a specified fixed length. As a result, a set of standard connectors or couplings, such as B. 45 or 90 degree bends are available to connect the sections of the transmission line together as required. Special struts and springs are also used to allow for the differential expansion and contraction of the inner and outer copper tubing used in the transmission line.
Twinaxial cable
Twinaxial cable (also known as twinax or twinax) has two central conductors contained within the core with a single outer core and dielectric instead of the traditional single conductor design of most coaxial cable types. Some benefits of Twin-Axial cables include reduced cable losses, greater protection from ground loops and capacitive fields, and a reduction in low-frequency magnetic noise. These cables are best suited for use in low frequency digital and video applications.
triaxial cable
Triaxial cables, also called triax, are coaxial cables to which an additional copper braid has been added. This braid acts as a shield and is grounded, directing ground loop currents or capacitive field noise away from the conductive elements of the inner core. Triaxial cable offers increased bandwidth and interference rejection, offers an improvement in signal-to-noise ratio over standard coaxial cable, and reduces cable loss and cable stress.
Other types of coaxial cable
Some other specialized types of coaxial cable are:
Custom coaxial cable design and manufacturing services are also available for special requirements.
How the coaxial cable is specified
Common specifications for coaxial cable include:
Cable type or RG type (which stands for Radio Guide) is now largely an obsolete reference because the underlying standard that defines these terms is no longer an active document. RG-6 is a very common type used in home video applications.
The inner core conductor material can be bare copper, silver plated copper, tin plated copper or aluminium/copper to name a few choices.
The impedance of the cable. The most common values for impedance are 50, 52, 75 or 93 ohms.
The jacket material that serves as the outer protective layer of the cable.
Key cable dimensions including length, outside diameter and wire size.
The desired connector configuration, which includes both the desired gender and the specific connector style such as BNC, SMA, SMB, or N-Type.
The minimum bend radius
The attenuation, measured in dB per unit length of cable
The nominal temperature for the cable
summary
This article provides a brief summary of the common types of coaxial cable and the parameters that define how a coaxial cable is specified. For other products, please see our additional guides or the Thomas Supplier Discovery Platform to find potential sources of supply or view details on specific products.
Sources:
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More from Electrical & Power Generation
How do I remove a coaxial cable lock?
- Insert the tissue paper inside the gap between the coaxial cable and the cable lock. …
- Insert the clip of the pen cap inside the tissue paper. …
- Press firmly against the pen cap, and turn the cable lock counterclockwise to remove.
How to Process & Fabricate Coax Cable
How do you remove the end of a coaxial cable?
Disconnect the coaxial cable from any equipment that it is attached to. Rotate the nut at the end of the cable in a counterclockwise direction. If you cannot turn it by hand, use an adjustable wrench or pliers.
How to Process & Fabricate Coax Cable
Semi Rigid Coaxial Cable Stripper – Winton Machine Company
See some more details on the topic semi rigid coax cable stripping tool here:
SemiRigid 1050 – Strip – Schleuniger
Programmable stripping machine for semi-rig coaxial cables up to 4.50 mm (0.177”) outer diameter and strip lengths up to 30 mm (1.18”).
Source: www.schleuniger.com
Date Published: 6/22/2022
View: 5516
Coaxial Cable Strippers – The Eraser Company
Semi Rig Coax cable has a metallic outer jacket (usually copper or aluminum), a dielectric, and an inner conductor and are stripped in 1 or 2 levels.
Source: www.eraser.com
Date Published: 4/10/2022
View: 7511
Tooling & Accessories – Mouser Electronics
Kits for semi-rig and flexible cables. … Kit for microporous semi-rig cables . … Fixed-blade coaxial cable stripping tool for cable dia.
Source: www.mouser.com
Date Published: 5/5/2022
View: 8827
Semi Rigid Coax Stripper
Product description
2022 Winton launches a new cutter head assembly
Improved design for more flexibility
The new design allows for more repeatable stripping of small diameter coax cables. The updated cutting head allows users to strip semi-rigid coaxial cable diameters up to 0.047 inch.
Improved concentricity adjustment allows the user to more easily maintain alignment between the cutting head and clamp assembly.
Next generation software is enhanced for more sophisticated stripping modes and better on-board diagnostics.
After the cutoff – stripping the ends
Once the cut lengths come off the saw with nice square ends, the ends of the cable can now be trimmed for a connector. Dressing the ends may involve multiple step cuts at each end. One of the most important quality features when truing cable ends is the removal of the outer jacket and insulator without notching the inner conductor. Here, an all-electric CNC semi-rigid coax stripper simplifies the process.
Winton’s coax stripper, model CS6, is designed to remove the outer jacket and insulator in a series of precise, seamlessly coordinated movements. This 2 axis CNC stripper uses high precision stepper motors to ensure the correct amount of material is removed leaving the center conductor unaffected. The touch screen makes it easy to program the final stripped lengths and diameters. The microprocessor does the rest. Precision and repeatability…that’s what you add to your manufacturing process by using a Winton coax stripper. Call us to find out more!
Stripping machines for coaxial, micro-coaxial, triaxial and conformable cable
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How to Process & Fabricate Coax Cable
How to process coaxial cable
Coaxial cable is a common means of transporting radio frequency signals in microwave communication systems. Coaxial cable can be found in commercial and military applications around the world. Everything from cell phone towers to ship-to-ship satellite communication systems uses coaxial cable. Two common types of coaxial cable are semi-rigid coaxial cable and flexible coaxial cable. Cutting, stripping the ends, and bending coaxial cable are discussed below for both cable types.
Cut
Cutting semi-rigid coaxial cable with a saw
Semi-rigid coaxial cables often come in straight lengths. When cutting semi-rigids, it is usually a saw cut. A saw-type cut is preferred as the next step in processing the coaxial cable is to dress the ends for fittings. If the ends are not square cut and/or have too much burr on the OD, the coax stripping machine may not accept the semi-rigid cable end for processing.
A thin, high-speed saw cuts through the semi-rigid cable with little effort. The outer jacket of a typical coaxial cable is made of copper or aluminum with a plastic insulator surrounding the center conductor. With the right number of teeth on the saw, production can continue as long as the saw blade stays sharp. As the blade becomes dull, the burr on the outside diameter tends to increase.
Cut quality isn’t the only QC trait to worry about. Cut length repeatability is most important. If the cut length varies too much, the VSWR will also change. It is most desirable to choose a cutting process that produces a square cut while cutting consistent lengths.
Cutting flexible coaxial cable with a saw system
Flexible coaxial cables are becoming increasingly common in commercial systems. Because it is flexible, the application in which the flexible cable is used can dictate whether the cable will be bent by hand or by a CNC machine. Despite this, flexible cable is supplied on a spool as opposed to semi-rigid cable. Getting it off the spool, measuring it, and cutting it to precise lengths requires a cutting system that straightens the cable first. After straightening, a saw cut can be made.
The same saw blade used to cut semi-rigid coax can be used to cut flexible coax. Care must be taken to ensure both sides of the cable are secured during the cutting process. Lack of support during the cutting process can lead to poor cutting results.
stripping
Once the cut lengths come off the saw with nice square ends, the ends of the cable can now be trimmed for a connector. Dressing the ends may involve multiple step cuts at each end. One of the most important quality features when truing cable ends is the removal of the outer jacket and insulator without notching the inner conductor.
Notching the inner conductor can lead to rejects. Therefore, choosing a stripping machine that is highly repeatable in terms of depth of cut and length stripped is paramount to proper signal transfer.
To bend
Consistent products that are delivered require consistent components. Hence the need to consistently bend coaxial cable. Consistent bending starts with a good set of bending tools. Coaxial cable bending tools include a bending coil, a clamping die and a wiping roller. A collet is required for CNC bending. Bending coax cables by hand can produce the same results as bending them with a CNC coax bender. The difference is that when bending by hand, the operator needs to stay focused to avoid quality problems later.
When choosing a centerline bend radius, first consult the literature on the manufacture of the coaxial cable. This is a good place to look for the minimum allowable bend radius. Flexible coaxial cable will retain its shape if bent to some degree. Flexible coaxial cables cannot absorb the G-forces that semi-rigid ones can and still retain their original shape. Still, flexible coaxial cable has its place in the market where the cost of goods sold is often an issue.
Quite often, long lengths of semi-rigid coaxial cable are loaded into a bender for processing. These long lengths are handled by the bending cycle using what is known as pull feed. The initial straight lengths can be longer than the bender itself. However, with the clutch feed built into the software, the bender can easily feed the coaxial cable.
When bending semi-rigid material from a long bar, a cut-off saw is usually mounted on the bending machine. After a specific configuration has been bent, the cut-off saw mounted on the bender can be used to separate the formed part from the long bar.
Quality concerns in coaxial cable manufacturing
The ability to consistently bend semi-rigid cable or flexible coaxial cable can affect the VSWR to some degree. Within the flex zone itself, additional surface defects such as dents on the outer jacket affect the VSWR. Dents or defects in the straight sections between turns can also cause the VSWR to change. Dents or surface defects found in semi-rigid or flexible cables are often the result of manual labor errors and are often due to:
Change in clamping pressure during the cutting and/or bending process
Variations in manual handling during the cutting and/or bending process
summary
Cutting, stripping and/or bending coaxial cable for industrial applications requires great care during the manufacturing process. A gentle touch coupled with consistent manufacturing processes can result in high quality coaxial cable assemblies destined for production.
About the author
George Winton, PE designs and builds CNC tube fabrication equipment for Winton Machine in Suwanee, GA. He can be reached at [email protected] or 888.321.1499.
About the machines we build
All of our semi-rigid coax and tube fabrication machines at Winton are designed, manufactured and tested in-house. We have a wide range of standard products and are able to design the best solution for our customers’ needs. Our experienced sales force ensures our customers can justify their capital investment by providing a solution that is exactly what they need to manufacture their parts. Please contact us today to discuss your project.
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