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China Xi'an Xu&Hui Electromechanical Technology Co., Ltd.
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Xi'an Xu&Hui Electromechanical Technology Co., Ltd.
Xi'an Xu&Hui Electromechanical Technology Co., Ltd. /Xian XZH Electric Power Technology Co., Ltd. has found in 2013, located in Xi'an, China. which is a highly experienced team dedicated to developing electrical measurement instrument, the product line covers a wide range of devices for testing various electrical area, such as underground cable fault locating system, power transformer test, AC/DC Hipot test, Insulation resistance test and so on. With rich measurement experiences of innovation combining and advanced technology to provide the most reliable electrical measurement. The design development production and Inspection is performed at the ISO 9001 and CE which gurantee a consistency of high quality products. XZH TEST masters a variety of technologies as well as extended service and support to deliver the highest value to our customers. We sincerely hold the tenet of "quality first, customers supreme, honor commitment trust worthy".Stays commitment R&D about electric power detection equipment and electric power automation, since its foundation, the company keeps living up to the belief of: "Create high-quality brand, casting first-class enterprise image". Also, we make the "steady development, the best quality "as the core concept of the enterprise. Our goal is to provide our customers with reliable test and measurement equipment that more safe and easy to use, we make measurement easier! Xi'an Xu & Hui Electromechanical Technology Co., Ltd expect to strengthen the relationship with world-wide cooperators, and warm-heartedly welcoming business partners to visit our factory for developing the OEM & ODM win-win Cooperation. Our Team Factory scene Training is a core course for all the members and we will organize various trainings to help us to improve our abilities and Let us find the beauty of life. We treasure the time we are learning and studying together. Services We have the ability to innovate new products and technologies. We can provide complete system solutions for your project. We provide online and offline practical and theoretical training. We provide instrument repair and calibration. Certification
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What are the causes of errors in cable fault detector equipment? 2025-08-26 While cable fault detectors offer a certain degree of convenience in cable fault detection, in practice, various uncertainties can lead to deviations in detection results. So, what are the causes of cable fault detector errors? Cable Fault Detector Human Error Currently, cable fault detectors based on the traveling wave method primarily rely on testers to determine the distance to the fault by analyzing the fault detection waveform. User interpretation errors can sometimes lead to detection errors, often due to the tester's experience. These errors primarily stem from the application of the detection method, the test voltage level, wiring details, and the determination of waveform inflection points. This is a major reason why cable fault detection is more difficult than other electrical equipment faults. Due to the irregularities and complexity of cable fault detection waveforms, truly automatic fault location calculation is currently difficult. Cable Fault Detector Cable Error This error is primarily caused by the propagation speed (V) of radio waves along the cable under test. The formula L = (U*T)/2 shows that the cable fault detection distance L is directly proportional to V. In cable fault detection, V is considered a constant, a relative concept, not an absolute value. Actual measurements and relevant data indicate that the transmission velocity V generally exhibits a relative error of ±2%. For example, the transmission velocity V of XLEP cable is approximately 172.3 m/s. There are two reasons for this error: First, the same type of cable produced by different manufacturers may exhibit errors due to factors such as production processes and ingredients. Second, cable insulation aging causes V to vary. Currently, there is no accurate data to explain this variation. Note: There may be inconsistencies between the marked length, actual length, and test length of the cable being tested. Cable Fault Detector Environmental Error After a rough cable fault is detected, the distance along the cable is typically measured based on the detected distance data. However, due to adverse environmental conditions (such as rivers, ditches, buildings, etc.) and the winding nature of buried cables, accurate measurement is extremely difficult, and often only a very rough location can be determined. This error, also known as measurement error, is often an unpredictable source of error. Therefore, establishing and improving detailed power cable records is crucial, and digital management of pipeline networks using GIS will become even more essential in the future. Cable Fault Detector In addition to the aforementioned factors, cable fault detector errors can be caused by other factors, such as equipment failure. To avoid errors in cable fault detector detection, careful data analysis is required during testing.
Development Trend of Power Cable Diagnosis and Testing Technology 2025-08-26 [Summary] Power cables, whether installed on machinery or buried underground, are subject to inevitable failures after prolonged use, disrupting the lives of citizens and businesses. Serious failures can even cause serious fires and casualties. Power cables, whether installed on machinery or buried underground, are subject to inevitable failures after prolonged use, disrupting the lives of citizens and businesses. Serious failures can even cause serious fires and casualties. Buried power cables are highly concealed, making fault detection and accurate location difficult, hindering cable maintenance. Given the significant role of power cables in urban areas and their unique characteristics, power cable diagnostic testing technology has attracted considerable attention from industry insiders. 1. Overview of Power Cable Diagnostic Testing Technologies1.1 Traditional Testing TechnologiesThe DC superposition method, DC component method, and TGδ dielectric loss method are all commonly used traditional power cable testing methods. While their application value cannot be completely denied and they do provide reference for diagnosing power faults, these traditional technologies are ultimately unsuitable for the testing and diagnosis of ultra-high voltage power cables, significantly limiting their scope of application.1.2 New Testing Technologies① Cable Joint Testing TechnologyA statistical survey of power cable failures in operation found that over 90% of cable failures occur at cable joints. Overload and contact resistance in operating power cables can cause joint temperatures to rise, leading to rapid aging and failure. Using cable joint testing technology to measure joint temperature and analyze it based on real-time joint temperature data provides a more comprehensive understanding of the power cable's operating status, enabling proactive preventative measures to reduce the likelihood of failures.② Ultra-High Frequency Testing TechnologyIf a power cable experiences a high localized discharge pulse frequency, capturing that localized discharge signal requires increasing the testing tool's sampling frequency to minimize external noise contamination. Ultra-high frequency detection technology utilizes wideband partial discharge sensors and electromagnetic coupling methods to detect partial discharge phenomena in the 10 kHz to 28 MHz frequency range with satisfactory detection results.③ Electromagnetic coupling technologyThis technology connects the partial discharge current signal of the grounding wire of a cross-linked polyethylene power cable with the two lines mentioned above through the interaction of a measurement loop and an electromagnetic coupling line. This amplifies the local signal and controls noise interference.2. Development and Application of Power Cable Diagnostic Testing Technology2.1 Online Detection Technology① Wavelet Transform: This technology requires the use of filters. Some studies have proposed two methods for measuring fault distances—single-ended detection and dual-ended synchronous detection. Other studies have used wavelet transforms for single-ended traveling wave ranging, resolving the issue of choosing between traveling wave propagation velocity and arrival time. Extensive practical experience has confirmed that the accuracy of this single-ended traveling wave ranging technology fully meets the standards for accurate fault location at the fault site. Other studies have explored online cable fault monitoring and precise cable distance measurement methods, and have delved into cable fault distance measurement using wavelet transform technology. ② Real-time expert system: This technology, developed based on network remote services, addresses cable fault location. Research indicates that expert systems based on relay protection can, through C language integrated diagnostics, identify the fault type and current RMS of power cables, ultimately pinpointing the fault location.③ Causal network: A causal network consists of nodes: symptoms, initial causes, states, and hypotheses. Symptom nodes represent the symptoms of state nodes, such as a protective action indicating a circuit breaker trip; initial causes represent the initial cause of a cable fault; state nodes represent the state of a specific domain, such as a circuit breaker fault; and hypotheses represent diagnostic hypotheses for the research system. Some researchers have expanded on the causal network, leveraging the concept of temporal constraints on alarm information to construct a new temporal causal network and have developed a power cable fault diagnosis technology based on this network.2.2 Offline Detection Techniques① Low-voltage pulse method: A low-voltage pulse signal is input into the cable through a test terminal. An instrument records the time difference (Δt (μs)) between the transmitted pulse and the reflected pulse received at the fault point, and then calculates the fault distance. If the signal propagation speed in a power cable is v (m/μs), then the cable fault distance l = v × Δt/2.② Pulse voltage method: This method receives a pulse signal generated by a discharge at the fault point. High-voltage equipment is used to cause a discharge at the fault point in the cable, generating a pulse signal. The instrument then receives the discharge signal from the fault point at the test end, and the distance to the fault point is calculated based on the time it takes to receive the signal. However, this method may pose safety risks because it does not completely isolate the electrical connection between the high-voltage section and the tester.③ Pulse current method: This method works similarly to the pulse voltage method, but uses a current coupler, completely isolating the high-voltage section, ensuring safety.④ Secondary pulse method: This is a highly advanced fault distance measurement method. The technical principle is to apply high voltage to the faulty cable, creating a high-voltage arc. This creates a low-resistance short circuit, which can then be detected using a low-voltage pulse method.2.3 Power Cable Fault Location TechnologyOnce the path and distance of the faulty cable are measured, the approximate location of the fault point can be determined. However, for more accurate fault location, fault location technology is required. ① Acoustic detection technology: A discharge device is used to generate vibrations at the fault point. Once the vibrations reach the ground, a vibration pickup is used to receive the acoustic signal from the fault point, allowing the specific location of the fault to be determined. Acoustic detection technology can be used for any cable fault detection where a high-voltage pulse signal generates a discharge sound at the fault point.② Acoustic-magnetic synchronization technology: Discharge at the fault point simultaneously generates both acoustic and electromagnetic waves, allowing for precise fault location. A high-voltage pulse signal is applied to the faulty cable. During discharge, both an acoustic signal and a pulsed magnetic field signal are generated at the fault point, but these signals propagate at different speeds. The minimum propagation time difference is used to locate the fault point.③ Audio sensing technology: Technicians use their ears to identify the strength of the acoustic signal and ultimately determine the location of the cable fault. An audio current signal of 1kHz or other frequency is applied between two phases of the cable, or between the metal sheath and a phase. This generates an audio electromagnetic signal, which creates a strong magnetic field directly above a nearby open-circuit fault or a metallic short-circuit fault, thereby locating the fault point.
Common cable faults and solutions 2025-08-26 1. IntroductionCables play a vital role in modern electrical and communications systems, serving as the backbone of power transmission and data connectivity. Whether in industrial plants, commercial buildings, transportation systems, or data centers, cables ensure the reliable flow of energy and signals from one point to another. However, cable failures are common due to environmental stress, mechanical damage, aging, or improper installation. These failures can lead to system downtime, equipment failure, and even safety hazards. Understanding the types and causes of cable failures, as well as effective detection and repair methods, is crucial to maintaining system integrity and operational efficiency. This article provides a comprehensive overview of common cable failures, including their identification, analysis, troubleshooting techniques, and prevention strategies. It is intended to provide a practical reference for engineers, technicians, and maintenance personnel working with electrical and communications infrastructure. 2. Cable Types and ApplicationsClassification by ApplicationPower Cables Power cables transmit electrical energy and are widely used in distribution systems such as substations, industrial facilities, and residential buildings. Power cables come in various voltage levels, including low voltage (LV), medium voltage (MV), and high voltage (HV), and may have properties such as fire resistance or flame retardancy for enhanced safety. Control Cables Control cables transmit control signals in automation systems and are crucial in production lines, machinery control panels, and building management systems. These cables are typically shielded to prevent electromagnetic interference (EMI) and ensure signal accuracy. Communication Cables These cables support data and signal transmission in telecommunications and networking applications. Common cable types include twisted pair, coaxial cable, and fiber optic cable. Fiber optic cable, known for its high bandwidth and low signal loss, is increasingly used in high-speed internet, cloud computing, and long-distance communication networks. Classification by Construction: Single-core vs. Multi-core Cables Single-core cables contain a single conductor and are typically used in high-voltage applications where flexibility is less important. Multi-core cables contain multiple conductors within a single jacket and are ideal for complex wiring systems in buildings and control circuits. Shielded vs. Unshielded Cables Shielded cables have a metallic layer that reduces electromagnetic interference and are often used in sensitive electronic environments. Unshielded cables are more cost-effective but are better suited for areas with less electromagnetic interference (EMI). Armored vs. Unarmored Cables Armored cables have an additional protective layer, typically made of steel or aluminum, to enhance mechanical strength and resist physical damage. These cables are often used in underground utilities or harsh industrial environments. Unarmored cables lack this protection and are suitable for indoor or lightweight applications. Typical Applications Industrial Automation: Control and signal cables connect PLCs, sensors, and actuators on production lines. Building Electrical Systems: Power cables power lighting, HVAC, and home appliances, while communications cables support security and smart building systems. Transportation Infrastructure: Railways and subways use specialized cables for traction power, signaling, and onboard systems. Data Centers: High-performance communications cables ensure fast and stable network connections between servers and storage devices. Renewable Energy Systems: At wind farms and solar power plants, power cables transmit the generated electricity to the grid and require durability under extreme conditions. Cables 3. Main Causes of Cable FailuresCable failures can be caused by a variety of internal and external factors. Identifying the root cause is crucial for effective troubleshooting, repair, and prevention. The most common causes include: Environmental FactorsEnvironmental conditions play a significant role in cable degradation. Exposure to extreme temperatures, humidity, UV radiation, and chemicals can accelerate insulation degradation and lead to failure. For example, water ingress can cause insulation breakdown, while prolonged exposure to sunlight can degrade the outer jacket. Mechanical DamagePhysical damage during installation, operation, or maintenance is a leading cause of cable failure. This includes: Excessive bending, exceeding the minimum bend radius Cable crushing or severing during excavation or construction Conductor breakage or insulation cracking due to improper handling This mechanical stress can compromise the cable's structural integrity and electrical performance. Manufacturing DefectsPoor-quality materials or substandard manufacturing processes can create weak points within the cable. These defects may not be immediately apparent but can lead to premature failure under normal operating conditions. Common problems include uneven insulation thickness, impurities in the conductor material, and inadequate shielding. Aging and Electrical StressCables naturally age over time due to thermal cycling, oxidation, and prolonged exposure to voltage stress. Repeated overloads or voltage surges (such as those caused by lightning strikes or switching operations) further accelerate this process. The insulation becomes brittle and fails, increasing the risk of short circuits and ground faults. Understanding these primary causes helps engineers and technicians implement better design, installation, and maintenance practices to minimize cable failures and extend system life. 4. Common Cable Fault TypesCable faults manifest in various ways, each with unique characteristics and impacts. Identifying the fault type is crucial for accurate diagnosis and appropriate corrective action. Open Circuit FaultsAn open circuit fault occurs when the continuity of a conductor is interrupted, preventing current from flowing. This is typically caused by a broken conductor, a loose connection, or a faulty termination. Symptoms include a complete interruption of power or signal transmission along the affected line. Short Circuit FaultsA short circuit occurs when two or more conductors accidentally come into contact, causing current to bypass the intended load. This results in excessive current, triggering protective devices (such as circuit breakers) and potentially damaging equipment. Common causes include insulation breakdown and physical damage. Ground FaultA ground fault occurs when current unexpectedly flows from a live conductor to the ground or a grounded surface. This is typically caused by insulation damage or moisture intrusion. Ground faults pose a serious safety risk and can result in electric shock or fire. Insulation FailureInsulation failure occurs when the insulation surrounding a conductor deteriorates or breaks down. This can lead to leakage current, partial discharge, or even complete insulation collapse. Aging, overheating, and environmental exposure are the primary causes of this type of failure. Termination and Connector FailureCable termination or connector failures are common in both power and data cables. Poor crimping, corrosion, or misalignment can increase contact resistance, leading to overheating and unstable connections. These failures are particularly common in systems that are frequently plugged and unplugged. Electromagnetic Interference (EMI)While not a direct physical fault, EMI can disrupt the signal integrity of communication and control cables. It is often caused by inadequate shielding, poor cable routing near high-voltage lines, or ungrounded metal parts. Symptoms include data corruption, signal distortion, and communication errors. By understanding these common cable fault types and their root causes, maintenance personnel can better diagnose the problem and apply targeted solutions to restore system performance. 5. Cable Fault Detection MethodsAccurately and efficiently detecting cable faults is crucial to minimizing system downtime and ensuring safe operation. Depending on the type and location of the fault, various testing and diagnostic techniques are required. Visual InspectionA basic but essential step in fault detection involves inspecting the cable's outer jacket and termination points for signs of physical damage, wear, or corrosion. While a visual inspection cannot identify internal problems, it can help detect obvious causes such as cuts or abrasions. Continuity and Resistance TestingUsing a multimeter or ohmmeter, a continuity test verifies the integrity of the conductor between two points. A high resistance reading may indicate a partial break or a poor connection. Insulation Resistance Testing (Megohmmeter Test)This test measures the resistance between a conductor and ground or between conductors to assess the condition of the insulation. A significant drop in resistance indicates possible insulation breakdown or moisture intrusion. Time Domain Reflectometry (TDR)TDR sends low-voltage pulses down the cable and analyzes the reflected signal. By measuring the time delay and amplitude of the reflections, TDR can locate opens, shorts, and impedance mismatches with high accuracy. High Voltage Withstand TestThis method, also known as dielectric strength testing, applies high voltage to the cable insulation to check its ability to withstand electrical stress without breakdown. This helps identify weak points that could lead to future failures. Partial Discharge TestPartial discharge (PD) testing, primarily used on medium and high voltage cables, detects tiny electrical discharges within the insulation. These discharges often precede complete insulation failure, making PD testing a valuable predictive maintenance tool. Infrared ThermographyThermal imaging cameras detect abnormal temperature patterns in cables and connectors. This non-contact technology allows for early detection of overheating caused by high resistance or overload. Used individually or in combination, these methods provide a comprehensive approach to effectively identify and locate cable faults. Cables 6. Solutions to Common Cable FailuresOnce a cable fault has been detected and analyzed, appropriate corrective actions must be taken to restore system functionality and prevent recurrence. Open-Circuit Failures: Replace the damaged section of cable or re-terminate the affected end. If the cause is mechanical stress, ensure proper routing and support during reinstallation. Short-Circuit Failures: Cut off the damaged section and install a new connector or splice. If the insulation failure is extensive, consider replacing the entire section of cable. If the failure is caused by environmental factors, use higher-grade insulation material. Ground Failures: Locate and repair any insulation breaks or moisture intrusion points. Seal the damaged area with waterproof tape or heat shrink tubing. If the condition is severe, replace the affected section with a more durable cable. Insulation Failures: Depending on the severity, repair the damaged insulation or replace the entire cable. Install protective conduit or use cable with improved heat and chemical resistance for increased protection against environmental stresses. Termination and Connector Failures: Re-crimp or re-solder the failed connection. Replace corroded or worn connectors. Apply an antioxidant paste to improve conductivity and prevent future performance degradation. Electromagnetic Interference (EMI): If interference is a problem, upgrade to shielded cable. Reroute the cable to avoid proximity to high-current lines. Ensure all shields are properly grounded. By applying these targeted solutions, technicians can restore cable performance and extend its life while addressing the root cause of each specific failure. 7. Prevention StrategiesPreventing cable failures requires a proactive approach, including proper design, installation, maintenance, and monitoring practices. Proper Cable Selection and InstallationChoosing the right cable for the application is crucial. Factors such as voltage rating, current capacity, environmental conditions, and mechanical protection need to be considered. During installation: Avoid sharp bends and excessive tensioning Follow minimum bend radius guidelines Use appropriate clamps and brackets to secure cables Regular Maintenance and TestingImplement a regular maintenance program, including: Visual inspection Insulation resistance testing Thermography Partial discharge analysis (for high-voltage systems) Regular testing can help detect early signs of performance degradation before it develops into a catastrophic failure. Environmental ProtectionProtect cables from harsh environmental conditions by: Using UV-resistant and flame-retardant jackets Installing cables in conduit or cable trays Sealing outdoor terminations to protect against moisture Personnel TrainingEnsure installation and maintenance personnel receive proper training on: Safe handling procedures Proper use of test equipment Standardized termination and splicing techniques Well-trained personnel significantly reduce the risk of failures related to human error. Using Monitoring SystemsModern cable monitoring systems provide real-time data on: Temperature Load current Insulation condition These systems enable predictive maintenance and help prevent unexpected failures. Adopting a comprehensive preventative strategy not only reduces downtime but also improves overall system reliability and cost-efficiency. ConclusionCables are essential components in electrical and communications systems, and their reliability directly impacts the performance and safety of the entire infrastructure. Understanding common cable fault types—including breaks, shorts, ground faults, and insulation faults—is key to effective troubleshooting and repair. Failures can arise from a variety of causes, such as environmental exposure, mechanical damage, manufacturing defects, and long-term aging. Identifying these causes facilitates more accurate diagnosis and targeted corrective action. A variety of inspection methods, including visual inspection, insulation resistance testing, TDR, and infrared thermography, provide reliable tools for fault location and diagnosis. Once the fault is identified, appropriate solutions, such as cable replacement, splicing, connector repair, or EMI mitigation measures, can be implemented to restore system integrity. Preventive measures—from proper selection and installation to regular maintenance, environmental protection, and personnel training—play a vital role in minimizing the occurrence of cable failures. Implementing intelligent monitoring systems can further enhance fault prediction and response capabilities. By combining technical knowledge with best practices in design, installation, and maintenance, engineers and technicians can ensure the long-term reliability and safety of cable systems across various industries.
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