KSM-S (N)SHTÖU-J + FO Reeling Crane Cable – Durable, High-Speed Solutions for Heavy-Duty Applications

In today's demanding industrial landscape, the selection of appropriate reeling cables for crane systems and heavy machinery operations is crucial for maintaining operational efficiency and safety. The KSM-S (N)SHTÖU-J and KSM-S (N)SHTÖU-J + FO reeling cables represent cutting-edge solutions specifically engineered for applications requiring frequent winding and unwinding operations under extreme mechanical stress. These specialised cables are designed to withstand the rigorous demands of modern industrial environments whilst delivering exceptional performance in high-speed, dynamic applications.

The significance of choosing the right reeling cable cannot be overstated, particularly in applications where cables are subjected to simultaneous tensile stress, torsional forces, and forced cable guidance. Poor cable selection can lead to premature failure, costly downtime, and potential safety hazards in critical industrial operations. The KSM-S series addresses these challenges through advanced engineering and premium materials, making them ideal for crane systems, mining operations, construction sites, and various industrial applications where reliability is paramount.

Cable Structure & Features

The KSM-S (N)SHTÖU-J and KSM-S (N)SHTÖU-J + FO cables feature a sophisticated multi-layer construction designed to deliver superior performance in demanding reeling applications. The conductor material consists of bare copper strands conforming to Class 5 specifications according to DIN VDE 0295 and IEC 60228 standards, ensuring optimal electrical conductivity and flexibility for dynamic applications.

The core insulation utilises a specialised rubber compound that provides excellent electrical properties whilst maintaining flexibility under repeated flexing cycles. For the fibre optic variant (KSM-S (N)SHTÖU-J + FO), gradient index fibres measuring 62.5/125 µm are housed within gel-filled PETP tubes, which are then encased in a heat-resistant plastic sheath. This configuration ensures reliable data transmission even under extreme mechanical stress.

Core identification follows VDE 0293-308 standards, featuring colour-coded cores with green-yellow protective conductors for easy installation and maintenance. The overall core assembly includes strategically positioned protective conductors and fibre optic elements within the cable interstices, optimising space utilisation whilst maintaining structural integrity.

The inner sheath comprises a special rubber compound that provides additional protection against mechanical damage and environmental factors. A crucial component of the cable's design is the torsion protection braid, constructed from polyester fibres in an open support weave configuration. This feature significantly enhances the cable's resistance to twisting forces commonly encountered in reeling applications.

The outer sheath utilises a premium special rubber compound in black colouration, providing exceptional resistance to environmental factors including oil, chemicals, and temperature extremes. The cable surface features clear identification printing for easy recognition and traceability in industrial installations.

Special Features & Benefits

The KSM-S cable series incorporates several distinctive features that set it apart from conventional reeling cables. Most notably, these cables are manufactured completely free from lacquer-damaging substances (LBS) and silicone compounds during production, making them suitable for use in sensitive industrial environments where contamination could affect finishing processes or electronic equipment.

One of the most impressive characteristics of these cables is their exceptional speed tolerance, capable of operating reliably at speeds up to 180 metres per minute. This high-speed capability makes them particularly suitable for modern crane systems and automated material handling equipment where rapid cable deployment and retraction are essential for operational efficiency.

The cables demonstrate remarkable mechanical strength with a continuous tensile load capacity of up to 20 N/mm². However, for applications involving high mechanical stresses, particularly those with significant dynamic tensile forces resulting from high acceleration rates, the permissible stress levels should be determined on a case-by-case basis to ensure optimal performance and longevity.

For the fibre optic variant, the inclusion of gradient index fibres enables flawless data transmission capabilities. At 850nm wavelength, the optical fibres achieve an attenuation coefficient of just 3.3 dB/km with a modal bandwidth exceeding 200 MHz x km. At 1300nm, performance improves further with an attenuation coefficient of 0.9 dB/km and modal bandwidth exceeding 500 MHz x km. These specifications ensure reliable high-speed data communication in modern automated systems.

Applications

The versatility of KSM-S reeling cables makes them suitable for an extensive range of applications across various industrial sectors. These cables excel in dry, humid, and wet environments, demonstrating exceptional performance both indoors and outdoors. Their robust construction makes them particularly valuable for construction sites where cables are exposed to harsh conditions and mechanical abuse.

In industrial and agricultural operations, these cables provide reliable power and data transmission for mobile equipment and machinery. The mining industry benefits significantly from their durability and resistance to environmental factors, whilst crane applications represent perhaps their most demanding use case, where cables must withstand constant winding, unwinding, and dynamic loading cycles.

The fibre optic variant proves invaluable in applications requiring simultaneous power delivery and high-speed data communication. Modern automated crane systems, robotic material handling equipment, and intelligent industrial machinery rely on the dual functionality provided by the KSM-S (N)SHTÖU-J + FO configuration.

Port operations, steel manufacturing facilities, and large-scale construction projects represent prime applications where these cables deliver significant operational advantages. Their ability to maintain performance integrity under extreme mechanical stress makes them particularly suitable for applications involving heavy loads and rapid acceleration cycles.

Performance Characteristics

The electrical performance specifications of KSM-S cables reflect their suitability for demanding industrial applications. With a nominal voltage rating of Uo/U: 0.6/1 kV and test voltage of 2.5 kV, these cables meet stringent electrical safety requirements for industrial power distribution systems.

Current carrying capacity calculations follow DIN VDE standards, ensuring safe and efficient power transmission across all conductor sizes. The temperature performance envelope spans from -40°C to +80°C for both fixed and moving installations, with conductor temperatures permitted up to +90°C under normal operating conditions.

Bending radius specifications follow DIN VDE 0298 Part 3 requirements, with separate specifications for fixed and moving applications. This ensures optimal cable life whilst maintaining electrical and mechanical performance throughout the service life.

Fire performance characteristics include self-extinguishing and flame-retardant properties according to IEC 60332-1 standards, providing enhanced safety in industrial environments. Oil resistance meets EN 60811-2-1 specifications, ensuring reliable performance in industrial environments where hydraulic fluids and lubricants are present.

Compliance with major international standards provides confidence in system design and installation. RoHS conformity ensures environmental responsibility, whilst CE marking under the 2014/35/EU Low Voltage Directive confirms compliance with European safety requirements.

Why Choose KSM-S Cables for Crane and Reeling Systems

The selection of KSM-S cables for crane and reeling applications offers numerous advantages that directly translate to improved operational efficiency and reduced maintenance costs. The exceptional mechanical properties ensure extended service life even under the most demanding conditions, whilst the high-speed capability enables faster operational cycles and improved productivity.

The dual-functionality of the fibre optic variant represents a significant advancement in crane cable technology. By combining power transmission with high-speed data communication capabilities in a single cable, the KSM-S (N)SHTÖU-J + FO eliminates the need for separate data cables, reducing installation complexity and potential failure points.

Reliability in harsh operational conditions stems from the careful selection of materials and advanced manufacturing processes. The special rubber compounds used throughout the cable construction provide superior resistance to environmental factors including oil, chemicals, temperature extremes, and mechanical abuse commonly encountered in industrial applications.

The torsion protection braid represents a critical design feature that significantly extends cable life in reeling applications. By distributing torsional forces throughout the cable structure, this feature prevents localised stress concentrations that typically lead to premature cable failure in dynamic applications.

For modern automated systems requiring precise control and monitoring capabilities, the flawless data transmission provided by the integrated optical fibres ensures reliable communication between control systems and mobile equipment. This capability supports advanced features such as load monitoring, position feedback, and predictive maintenance systems.

Frequently Asked Questions

Q: What makes KSM-S cables suitable for high-speed reeling applications?

A: KSM-S cables are specifically engineered with a torsion protection braid and special rubber compounds that enable reliable operation at speeds up to 180 m/min whilst maintaining structural integrity under dynamic loading conditions.

Q: Can these cables withstand oil contamination in industrial environments?

A: Yes, KSM-S cables meet EN 60811-2-1 oil resistance standards and are manufactured free from silicone compounds, making them suitable for use in environments where hydraulic fluids and industrial oils are present.

Q: What is the difference between KSM-S (N)SHTÖU-J and KSM-S (N)SHTÖU-J + FO variants?

A: The FO variant includes integrated gradient index optical fibres for high-speed data transmission alongside power conductors, whilst the standard version provides power transmission only.

Q: How do I determine the appropriate tensile load limits for my application?

A: Whilst the standard continuous tensile load capacity is 20 N/mm², applications with high dynamic forces or acceleration should be evaluated individually to determine optimal load limits and ensure maximum cable life.

Conclusion

The KSM-S (N)SHTÖU-J and KSM-S (N)SHTÖU-J + FO reeling cables represent the pinnacle of engineering excellence in industrial cable technology. Their unique combination of mechanical strength, high-speed capability, and environmental resistance makes them the ideal choice for demanding crane and reeling applications across various industrial sectors.

The integration of advanced materials, sophisticated construction techniques, and comprehensive quality standards ensures these cables deliver exceptional performance and longevity in the harshest operational environments. For the fibre optic variant, the addition of high-performance data transmission capabilities provides the foundation for modern automated systems requiring simultaneous power and communication functionality.

Industries requiring reliable, high-speed, heavy-duty reeling cable solutions will find the KSM-S series offers unmatched performance characteristics and operational advantages. The investment in premium cable technology pays dividends through reduced maintenance costs, improved operational efficiency, and enhanced system reliability, making KSM-S cables the preferred choice for critical industrial applications where failure is not an option.