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Design matters

Simplex MICC Manufacturing Process.

Simplex MICC is manufactured using engineered seamless extruded copper tubes, high purity magnesium oxide powder (MgO) and solid plain annealed copper class 1 conductors conforming to IEC 60228. There are many benefits to using a seamless drawn copper tube for the sheath over other methods,

  1. The geometry of the conductors remains consistent throughout the manufacturing process
  2. Conductors maintain the original round shape (Less distortion)
  3. As there is no weld there is no risk of an under bead encroaching towards the conductors.
  4. Stripping of the cables is easier as the sheath thickness is consistent.

The process itself is simple and controlled providing consistent results time and time again.

Firstly we run high purity powdered MgO through a grading and filter system to ensure consistency of particle size and remove any iron particles from the mix.

The Filtered MgO is then mixed to a paste and extruded under high pressure through a tungsten steel die to produce a concise one piece block The blocks are then subjected to a 3 stage sintering process in a high temperature kiln:

  1. stage 1: removes any traces of organic materials and liquids.
  2. stage 2: (diffusion) effectively closes the pores to create a considerably denser product with improved mechanical properties.
  3. Stage 3: controlled cooldown.

Simplex Micc

finalize and test the cable.

Once the seamless tubes have been filled with the conductor rods and MgO blocks, one end is then hydraulically swaged to allow it to pass through the first tungsten carbide die, these are precision ground and polished so that the necessary fine tolerances are maintained during the drawdown process. The drawdown reduces the diameter of the seamless copper tube while simultaneously crushing the MgO block around the conductors and setting the geometry for the conductors. The cable then passes through an annealing plant heating and cooling the cable so that it becomes soft and pliable prior to further drawdowns. This process is repeated until the cable reaches the required diameter.
Every coil of Simplex MICC are routine tested as called for under BS EN60702-1:2002. The coils are submerged in water for a minimum of 1 hour the ends are then stripped and sealed before high voltage testing is carried out. There are a number of further tests to confirm the cable meets the required standard:
  1. Insulation resistance
  2. Sheath Integrity
  3. Ovality
Sample tests are also scheduled to be carried out at regular intervals to add further peace of mind as to the performance of Simplex MICC.
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