Geometric Analysis and Manufacturing Considerations for Optimizing the Characteristics of a Twisted Pair

The geometry of a twisted pair largely determines its electrical characteristics. To improve and refine the value of these characteristics according to preset values, the optimization of the manufacturing processes requires comprehensive knowledge of twisted pair geometry and of how electrical magnitudes are affected by the construction features of the twisted pair. This paper studies the relation between the length of a twisted pair cable and the length of each of the wires that compose the cable, by analyzing concepts such as pitch angle and radius of the helix. In addition, it examines the deformations and irregularities that can occur in the twisted pair during the manufacturing process and their effects on the geometry of the twisted pair. Results showed in this paper are a part of a larger research project carried out in association with the R&D department of a cable manufacturing company, and these results are being applied into the design department of this company.