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.
Factor | Description | Importance |
---|---|---|
Flange Diameter | Total size of the cable reel | Determines the overall capacity of the reel |
Barrel Diameter | Size of the drum core of the reel | Affects the safe bending radius of the cable and reel capacity |
Traverse | Inner width of the cable reel | Determines how many rolls of cable can be stacked horizontally |
Cable Diameter | Thickness of the copper wire | Smaller diameter allows for more cable on the reel |
Edge Clearance | Height of free-board on flanges | Provides protection for the cable during shipping and storage |
Wire Gauge (AWG) | Standardized measurement of wire thickness | Smaller gauge number means thicker wire |
Maximum Reel Capacity | Total theoretical capacity of the reel | Calculated based on reel dimensions and wire thickness |
Recommended Reel Capacity | ~80% of maximum capacity | Accounts for manual winding variations and safety margin |
Current Capacity | Maximum amperage the wire can safely carry | Varies by wire gauge; important for electrical applications |
Copper Resistance | Electrical resistance per 1000 feet | Affects power transmission efficiency |
Cable Length | Total length of wire on the reel | Calculated based on reel dimensions and wire gauge |
Additional considerations:
- Winding tension can affect the actual amount of wire on a reel.
- Different copper types (bare, tinned, oxygen-free) may have slightly different properties.
- Regulations in some countries may dictate minimum edge clearance requirements.
- The relationship between wire gauge and diameter is inverse (smaller gauge number = larger wire diameter).
- 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.