Submarine Cables – Efficient Cleaning at High-Speed With Inline Ultrasonics
Submarine communication cables are the infrastructure of global connectivity – transmitting over 99% of intercontinental digital traffic. These cables must operate reliably in some of the most demanding environments on earth: deep ocean trenches, high-pressure saltwater exposure, and decades of non-stop operation. Cable cleaning is a challenging key step during manufacturing of submarine cables as surface cleanliness is a critical factor for signal transmission, insulation performance, and long-term durability. Hielscher ultrasonic inline cleaners are used by market leaders of cable manufacturing to ensure a fast and efficient removal of dirt and processing residuals for superior cable quality.
Ultrasonic Inline Cleaning: A High-Performance Solution for Submarine Communication Cables
Hielscher ultrasonic inline cleaning systems are designed for continuous, contactless cleaning of endless profiles such as:
- Conductive wire cores (e.g., copper, silver-coated, or aluminum)
- Shielding elements (braids, foils, tapes)
- Cable jackets prior to extrusion or coating
Ultrasonic inline cleaning system for the continuous removal of dirt and drawing oils from endless profiles
The process uses high-power ultrasound waves at 20khz to generate controlled cavitation in a liquid medium. Intense vibration and cavitation dislodges from the cable unwanted deposits such as:
- Drawing lubricants
- Oxide films
- Dust and particulates
- Residual processing chemicals
By integrating inline ultrasonic cleaners directly into the cable production workflow, Hielscher systems provide real-time cleaning without halting or slowing down the cable production.
Application fields of the Hielscher ultrasonic inline cleaners
- Endless profiles
- Wires
- Rods
- Strips
- Fibres
- Medical wires
- Copper wires and threads
- Punched metal strips
- Bond wires
- Solder wires
- Welding wires
- Threaded spindles and rods
- Precious metal wires
- Other endless materials
Ultrasonic Inline Cleaning in Submarine Cable Production
With decades of experience in ultrasonic process technology, Hielscher Ultrasonics is the trusted partner to manufacturers of high-value endless profiles worldwide. Precision German engineering ensures inline cleaning machines at industrial-grade reliability for non-stop 24/7 production. The robust design reduces maintenance to a minimum. Intense ultrasound ensures a in-depth contact-less cleaning – even at high line speeds.
From conductor strands to final assembly, Hielscher systems integrate seamlessly – helping your production line meet the technical and environmental demands of the submarine cable industry. The small foot-print of Hielscher ultrasonic inline cleaners allow the easy retro-fitting into existing cable production lines.
The ultrasonic cleaner module USCM700 and the ultrasonic 4-tank cleaner DRS2500-4S are two of Hielscher’s most popular inline cleaning systems.
Schematic plan of a inline wire cleaning system with ultrasonic processor, wire cleaning sonotrode, tanks, pumps, filters, rinsing, air wipes, and ceramic guide.
Ultrasonic inline cleaning system USCM700 for intense cleaning of endless materials such as solder wires.
- high efficiency, high throughput
- adjustable amplitude for best effects
- high amplitudes of up to 20 μm for intense cleaning
- removes even heavy, sturdy contamination
- contact-less, yet mechanical cleaning method
- for various diameters
- operation with water or mild cleaning agents
- robust belt filter (optional)
- air wipes for drying
- continuous operation
- robustness
- low maintenance
- built for 24/7/365 operation
Clean submarine cables means better communication quality.
Hielscher Ultrasonics makes it possible!
Ultrasonic cleaning system USCM700 with continuous belt filter
Literature / References
- Brochure “Ultrasonic Wire Cleaning – Hielscher Ultrasonics
- Leighton, Timothy; Birkin, Peter; Offin, Doug (2013): A new approach to ultrasonic cleaning. International Congress on Acoustics, January 2013.
- Fuchs, John F. (2002): Ultrasonic Cleaning: Fundamental Theory and Applications. In: Proceedings of Precision Cleaning May 15-17, 1995, Rosemont, IL, USA.
Frequently Asked Questions
What are the Steps in the Manufacturing Process of Submarine Communication Cable?
Submarine cable manufacturing involves sequential processes including conductor wire drawing, stranding, insulation and shielding extrusion, application of water-blocking layers, incorporation of optical fibers, armoring, jacketing, and final testing. Each stage is performed under strict environmental and mechanical controls to ensure structural integrity, dielectric performance, and long-term reliability under deep-sea conditions.
What are the Raw Materials for the Production of Submarine Cables?
Key raw materials include high-purity copper or aluminum for conductors, optical glass for fiber cores, polyethylene or cross-linked polyethylene for insulation, steel wire or aramid yarn for mechanical armoring, and bituminous or water-blocking compounds for environmental protection. Material selection depends on cable type, transmission load, and oceanic deployment conditions.
What is the Drawing Process in Cable Manufacturing?
Wire drawing is a metalworking process wherein a rod of copper or aluminum is pulled through a series of progressively smaller dies to reduce its diameter and increase tensile strength. The process ensures dimensional uniformity, surface smoothness, and the necessary mechanical properties for conductor fabrication in high-performance cables. Ultrasonically assisted wire drawing facilitates and accelerates the process step of wire drawing.
What is the Lifetime of a Submarine Cable?
Modern submarine communication cables are engineered for a service life of approximately 25 years. This lifespan is governed by factors such as electrical loading, mechanical stress, insulation degradation, marine environmental exposure, and the robustness of protective layers applied during manufacturing. Since the repair of submarine cables is highly complex and expensive, the quality control during manufacturing is essential in order to produce robust and reliable cables.
Hielscher Ultrasonics manufactures high-performance ultrasonic homogenizers from lab to industrial size.