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What are stranded wires?

In electrical engineering, a stranded wire, also known as litz wire,  is an easily bendable electrical conductor consisting of thin individual wires. Copper is predominantly used as the conductor material. Litz wires can be divided into flexible and highly flexible litz wires.

A stranded wire consists of individual, sometimes up to hundreds of thin copper wires. A 1.5 mm² H07V-K stranded wire, for example, is typically made up of 30 x 0.25 mm individual strands that are twisted into a bundle. A plastic sheath holds the bundle of individual wires together. It also serves as insulation for the copper strand.

The structure of a stranded wire is defined by standards. One of these standards is IEC 60228/VDE 0295. The plastic sheath is made of different materials depending on the application. For a H07V-K stranded wire, polyvinyl chloride (PVC) is used as standard. Depending on the cross-section, finished stranded wire can then be used for both –  signal and power transmission.

Advantages of stranded conductors over solid wire conductors

Compared to a conventional copper wire, stranded conductors have the advantage of being much more flexible and bendable. The reason for this is their composition of many fine wires. Compared to solid wire conductors, the risk of conductor breakage is much lower with stranded conductors. Such a break can occur, for example, due to mechanical stresses caused by vibration or bending.

Copper stranded conductors are therefore preferably used for the electrical connection of moving components, for example in areas subject to vibration. These include doors or trunk lids, vehicles or robots. Besides that there are also other areas of application for stranded wires.

Applications of stranded wires

Stranded wires are used as electrical connections in vehicles, in mechanical engineering, in automatic machines and in medical technology for respirators or MRI equipment. Litz wires are also used in control cabinet wiring as well as in renewable energies. 

We are happy to advise you on this and equip you with individual stranded wire variants. All copper wires are available in the desired length in meters and in various colors.

Production of assembled stranded wires with semi- or fully automated processes.

Stranded wire harnessing is the simplest form of cable assembly. Assembling is the technical term for the processing of the ends of a stranded wire that has been cut to length. The harnessing process usually involves the following steps:

  • removal of the insulation from the stranded wire ends
  • soldering or crimping electrical contacts to the stranded wire ends on one or both sides
  • screwing into screw terminals

Other connection techniques of electrical contacts to stranded wire ends are, for example, crimping, insulation displacement technology, screw terminal technology, ultrasonic welding or dip tinning.

Depending on the number of pieces, these processes can be carried out manually with manual tongs as well as semi-automatically or fully automatically.

The CiS Group assembles customer-specific, high-quality products such as stranded wires, cables and cable harnesses in compliance with standards and legal guidelines. Our experts  are happy to answer any questions you may have.

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