Copper Reel Fill Calculator

Copper Reel Fill Calculator

Based on the search results and the query, I’ll create a comprehensive table summarizing key information about copper reel fill calculations. This table will include important factors and considerations for determining the amount of copper wire that can be wound onto a reel.

FactorDescriptionImportance
Flange DiameterTotal size of the cable reelDetermines the overall capacity of the reel
Barrel DiameterSize of the drum core of the reelAffects the safe bending radius of the cable and reel capacity
TraverseInner width of the cable reelDetermines how many rolls of cable can be stacked horizontally
Cable DiameterThickness of the copper wireSmaller diameter allows for more cable on the reel
Edge ClearanceHeight of free-board on flangesProvides protection for the cable during shipping and storage
Wire Gauge (AWG)Standardized measurement of wire thicknessSmaller gauge number means thicker wire
Maximum Reel CapacityTotal theoretical capacity of the reelCalculated based on reel dimensions and wire thickness
Recommended Reel Capacity~80% of maximum capacityAccounts for manual winding variations and safety margin
Current CapacityMaximum amperage the wire can safely carryVaries by wire gauge; important for electrical applications
Copper ResistanceElectrical resistance per 1000 feetAffects power transmission efficiency
Cable LengthTotal length of wire on the reelCalculated based on reel dimensions and wire gauge

Additional considerations:

  1. Winding tension can affect the actual amount of wire on a reel.
  2. Different copper types (bare, tinned, oxygen-free) may have slightly different properties.
  3. Regulations in some countries may dictate minimum edge clearance requirements.
  4. The relationship between wire gauge and diameter is inverse (smaller gauge number = larger wire diameter).
  5. Actual reel fill may vary due to factors like winding technique and wire flexibility.

This table provides a comprehensive overview of the factors involved in copper reel fill calculations, combining information about reel dimensions, wire properties, and practical considerations for accurate estimation of wire length and reel capacity.

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