High Voltage Composite Reeling Cable | Integrated Power, Control Signal and Fiber Optic Transmission Cable
The RST-HVCR Series is a high voltage composite reeling cable designed for heavy-duty mobile equipment. It integrates high-voltage power, control signals, and fiber optic transmission in one durable cable, optimized for frequent reeling and dynamic movement.
Key Benefits:
- ✅ All-in-One: High voltage power + control + fiber optic
- ✅ Superior reeling durability for continuous winding/unwinding
- ✅ Excellent resistance to torsion, tension, and abrasion
- ✅ Ideal for TBM, mining machines, port cranes, and marine winches
High Voltage Composite Reeling Cable | Integrated Power, Control Signal and Fiber Optic Transmission Cable
The RST-HVCR series high voltage composite reeling cable is specially designed for heavy-duty mobile equipment. It enables simultaneous high-power transmission, control signals, and high-speed fiber optic communication in a single robust cable, optimized for frequent reeling, winding/unwinding, and dynamic movement.
Key Benefits
- All-in-One Integration：High voltage power + control/signal + fiber optic transmission
- Superior Reeling Performance：Engineered for long-cycle winding/unwinding with excellent torsion and tension resistance
- Enhanced Durability：Outstanding mechanical protection against abrasion, oil, and harsh industrial environments
- Wide Application：Ideal for TBM, mining machinery, port cranes, marine winches, and other heavy mobile systems
High Voltage Composite Reeling Cable | Integrated Power, Control Signal and Fiber Optic Transmission Cable
The High Voltage Composite Reeling Cable is engineered for demanding reeling applications where traditional separate cables are inefficient or unreliable. It is specifically developed for equipment such as tunnel boring machines (TBM), mining excavators, stacker-reclaimers, harbor cranes, offshore winches, and other heavy mobile systems that require high-power supply combined with real-time control, monitoring, and high-bandwidth data transmission during continuous reeling operations.
In high-voltage reeling systems, common failure modes include insulation breakdown under high voltage and mechanical stress, signal interference, fiber optic microbending or breakage, and overall cable fatigue from repeated torsion and tension. This composite reeling cable addresses these challenges through layered high-voltage insulation, optimized stranding, robust armor or reinforcement, and carefully protected optical fiber units.
The result is a single, high-performance cable that reduces installation complexity, minimizes cable management issues, and significantly improves system reliability and uptime in harsh industrial environments.
Designed For
This cable is intended for:
- High-voltage power supply with simultaneous control and data transmission
- Frequent reeling/winding on drums or cable reels
- Mobile heavy equipment with long travel distances
- Applications requiring real-time video, telemetry, or fiber communication
- Harsh environments with high mechanical stress, oil, moisture, or dust
This cable should be evaluated separately for:
- Extremely high torsion angles without proper reeling control
- Ultra-high voltage levels beyond specified ratings
- Applications with extreme bending radii or unsupported hanging lengths
- Environments requiring specialized chemical resistance not covered in standard designs
Product Summary
| Item | Description |
|---|---|
| Product Type | High Voltage Composite Reeling Cable |
| Main Use | Integrated high power + control/signal + fiber optic transmission in reeling systems |
| Typical Installations | TBM, mining machinery, port cranes, marine winches, stacker-reclaimers, heavy mobile platforms |
| Core Design | Multi-layer composite construction (Power + Control/Signal + Fiber Units) |
| Conductor Type | High-purity copper with high-voltage insulation |
| Jacket Type | Robust PUR or CR (Chloroprene) outer sheath with reinforcement |
| Movement Type | Reeling, winding/unwinding, dynamic torsional movement |
| Supply Form | Cut length, custom reel, project supply |
Typical Product Series
Series Name: RST-HVCR Series Category: High Voltage Composite Reeling Cable for integrated power, control and optical transmission
| Product Model | Product Name | Typical Configuration | Typical Use | Fiber Option | Jacket |
|---|---|---|---|---|---|
| RST-HVCR-3+3+FO | 3.6/6kV or 6/10kV Composite | 3 power + 3 control + FO | TBM and mining power + data | Multi-mode/Single-mode | PUR/CR |
| RST-HVCR-3+4+FO | High Voltage Reeling Composite | 3 power + 4 control/signal + FO | Port cranes and winches | Custom fiber count | Reinforced PUR |
| RST-HVCR-HP | Heavy Duty Hybrid Reeling | Custom power + signal + fiber | Offshore and heavy industrial | High core count FO | CR with armor |
| RST-HVCR-SP | Special Composite Reeling | Project-specific integration | Custom mobile equipment | Custom | Application-matched |
| RST-HVCR-C | Custom High Voltage Composite | Fully custom | Large-scale projects | Custom | Custom |
Technical Parameters
The values below are typical. Final specifications must be confirmed according to voltage rating, power requirements, fiber type, movement parameters, and environmental conditions.
| Parameter | Typical Range / Description |
|---|---|
| Voltage Rating | 3.6/6kV, 6/10kV, higher on request |
| Power Conductor Size | 10 mm² – 240 mm² or larger |
| Control/Signal Cores | 2.5 mm² – 10 mm², shielded options |
| Fiber Optic Units | 2–24 fibers (Single-mode or Multi-mode) |
| Conductor Material | High-purity stranded copper |
| Insulation | High-voltage XLPE or EPR |
| Shielding | Overall screen + individual pair shielding |
| Outer Sheath | PUR / CR / CSP for abrasion, oil and weather resistance |
| Reinforcement | Steel wire braid or aramid for tensile strength |
| Reeling Cycles | Designed for high cycle life (application dependent) |
| Temperature Range | -40°C to +80°C (or project specific) |
| Minimum Bend Radius | 10–15 × outer diameter (reeling optimized) |
| Application Scope | High power + control + real-time fiber data transmission in mobile reeling systems |
Cable Construction
High Voltage Power Cores
Optimized stranding and high-grade XLPE/EPR insulation ensure stable power transmission under mechanical stress and high voltage.
Control and Signal Pairs
Individually shielded twisted pairs maintain signal integrity in electrically noisy environments near high-power lines.
Integrated Fiber Optic Units
Optical fibers are placed in protected central or stranded units with adequate slack and cushioning to prevent microbending or breakage during reeling.
Robust Inner Layers and Fillers
Special fillers and binding tapes maintain roundness and stability during repeated torsional and tensile stress.
Durable Outer Sheath with Reinforcement
Heavy-duty PUR or CR sheath combined with braid or armor provides superior abrasion, tear, and tension resistance required for drum reeling.
Why Composite Reeling Construction Extends Cable Life
A reliable high-voltage reeling cable must handle simultaneous electrical, mechanical, and optical stresses. Integrated design with proper layering and protection achieves:
- Reduced conductor and insulation fatigue under high voltage + movement
- Maintained signal and fiber integrity through stable core positioning
- Superior protection against external mechanical damage
- Simplified cable management leading to lower maintenance and higher uptime
Reeling Application Boundary
This cable is suitable for:
- Drum reeling with controlled tension and speed
- Mobile equipment with combined power and data needs
- Long travel distances in guided or semi-guided paths
- Industrial environments with oil, moisture, and mechanical wear
This cable requires separate confirmation for:
- Extreme high-torsion free-hanging applications
- Very high voltage (>35kV) or ultra-high power demands
- Specialized explosion-proof or subsea requirements
- Applications with undefined or extremely aggressive chemical exposure
Typical Applications
The High Voltage Composite Reeling Cable is commonly used in:
- Tunnel Boring Machines (TBM)
- Mining excavators and continuous miners
- Port and harbor cranes
- Marine winches and offshore equipment
- Stacker-reclaimers and bulk material handling systems
- Heavy-duty mobile cranes and gantry systems
- Large-scale automated industrial platforms
Typical Working Conditions
- Frequent reeling/unreeling cycles
- High mechanical tension and torsion
- Exposure to oil, dust, and weather
- Need for real-time monitoring and high-bandwidth communication
High Voltage Composite Reeling Cable vs Traditional Separate Cables
| Comparison Item | Composite Reeling Cable | Traditional Separate Cables |
|---|---|---|
| Transmission Integration | Power + Signal + Fiber in one | Multiple independent cables |
| Installation Complexity | Simplified | Complex management |
| Mechanical Stress Handling | Optimized for reeling | Higher risk of entanglement |
| Signal/Fiber Protection | Better integrated shielding | More vulnerable |
| Maintenance & Uptime | Significantly improved | Higher downtime risk |
| Best Use | Heavy mobile high-voltage systems | Simple fixed or low-cycle use |
PUR/CR Sheath vs Standard Sheath
| Comparison Item | PUR/CR Reinforced Sheath | Standard Sheath |
|---|---|---|
| Abrasion & Tear Resistance | Superior | Moderate |
| Oil & Chemical Resistance | Excellent | Limited |
| Reeling Durability | Optimized for dynamic use | Better for static |
| Service Life in Harsh Conditions | Much longer | Shorter in heavy reeling |
Selection Guide
Correct selection depends on the actual operating parameters:
- Confirm Voltage and Power Requirements – Determine exact voltage class and conductor cross-section.
- Define Control/Signal Needs – Number and type of control pairs, shielding requirements.
- Specify Fiber Optic Requirements – Fiber count, type (SM/MM), and protection level.
- Assess Reeling Parameters – Drum diameter, travel length, speed, tension, and cycle frequency.
- Evaluate Environmental Conditions – Temperature, oil, chemicals, UV, abrasion level.
- Check Mechanical Demands – Required tensile strength, torsion resistance, and bend radius.
- Review Installation Layout – Reeling method, guiding system, and space constraints.
Customization and Supply
Custom construction is available for project-specific requirements.
Available Options
- Voltage rating and power conductor size
- Number of control/signal cores and shielding
- Fiber type, count, and configuration
- Sheath material and reinforcement level
- Cable diameter and length
- Custom marking and color coding
- Special connectors or terminations
Supply Support
- Technical consultation and model matching
- Sample production for testing
- Detailed drawings and compliance documentation
- OEM and large project supply
- Professional packing and fast delivery
Ordering Information
For faster quotation and accurate model selection, please provide:
- Voltage rating and power requirements
- Number of control/signal cores and fiber count/type
- Reeling drum parameters and travel distance
- Environmental conditions and expected cycle life
- Any special certifications or features required
Welcome to contact us! We will do our best to help you.
Shanghai Rousheng Wire and Cable Co., LTD Address: No. 2591 Fengzhe Road, Fengxian District, Shanghai, China Tel: +86-021-50759965 Email: Jerry@rstlkable.com WhatsApp: +8613482197396
