From 3,6/6 Kv up to 12/20 Kv with antitwisting protection
Ultra-High-Speed MV Reeling Cable
FLEXIDRUM® MEDIUM PLUS (N)TSCGEWÖU
Three-Phase High-Voltage Cable with Industry-Leading 300 m/min Performance
Nominal Voltage
3.6/6 kV
Up to 12/20 kV available
Max Speed
300 m/min
Industry leading + ±25°/m
Conductor Type
Bare Copper
Class 5, IEC 60228 standard
Bending Radii
6×D to 20×D
7-level classification system
Operating Temp
−50 to +80°C
Fixed, −35°C flexible
Weight Profile
2.5–12.1 kg/km
Compact 4-series range
Contents
- FLEXIDRUM PLUS Evolution: 300 m/min Breakthrough & Bare Copper Strategy
- Bare Copper vs. Tinned Conductors: Cost Optimization & Performance Trade-offs
- EPR GM1b Outer Sheath: Advanced Material Science & Thermal Management
- Phase-Earth Interleaved Architecture: Electromagnetic Optimization at 300 m/min
- Synthetic Fiber Anti-Twist Screen: Dynamic Torsion Performance at ±25°/m
- 300 m/min Ultra-High-Speed Dynamics: Centrifugal Stress & Fatigue Analysis
- −50°C to +80°C Extended Temperature Range: Cold-Weather Installation
- Four Series Variants (MR/QR/SR/UR): Cost/Performance Scaling Strategy
- Complete SKU Catalog: 27 Configurations & Electrical Parameters
- Forced-Guidance System Integration & Mobile Equipment Applications
1. FLEXIDRUM PLUS Evolution: 300 m/min Breakthrough & Bare Copper Strategy
The FLEXIDRUM® MEDIUM PLUS represents a fundamental engineering shift from the standard (N)TSCGEWÖU. The “PLUS” designation signals two critical innovations:
FLEXIDRUM PLUS Design Philosophy:Standard (N)TSCGEWÖU:
Max speed: 180 m/min
Conductor: Tinned copper (10–25 µm coating)
Voltage range: 3.6/6 kV to 20/35 kV (5 levels)
Weight: 2,110–14,400 kg/km (37 SKU range)
Target application: Standard forced-guidance systemsFLEXIDRUM MEDIUM PLUS:
Max speed: 300 m/min (+66% SPEED INCREASE)
Conductor: Bare red copper (cost optimization)
Voltage range: 3.6/6 kV to 12/20 kV (4 levels)
Weight: 2,540–14,400 kg/km (27 SKU range)
Target application: Ultra-high-speed mobile reel systems
Engineering Trade-offs:(1) Bare copper selection rationale:
Cost reduction: Tinned coating adds ~3–5% material cost
At 300 m/min extreme speed environment:
– Cable lifespan limited by mechanical fatigue, not oxidation
– Project duration (tunneling, mining): 5–10 years maximum
– Oxidation layer buildup (<0.5 µm over 5 years in sealed cable)
- Negligible impact on contact resistance in sealed environment
Result: Bare copper justifiable for PLUS line (cost-optimized, speed-focused)
(2) Voltage range reduction (5 levels → 4 levels):
Removed: 20/35 kV ultra-high voltage variant
Reason: 300 m/min speed + 20/35 kV insulation = excessive cable diameter
(would exceed 90–100 mm OD, too stiff for reeling)
Retained: 3.6/6, 6/10, 8.7/15, 12/20 kV (covers >90% of market applications)
(3) Speed multiplication factor:
Centrifugal force scales as v²
180 m/min: F ∝ (180)² = 32,400
300 m/min: F ∝ (300)² = 90,000
Stress ratio: 90,000/32,400 = 2.78× (nearly 3× higher radial stress)
Cable design response:
– Phase-earth interleaved core layout (maintains flexibility at high speed)
– Bare copper conductors (lower bending stiffness vs. tinned)
– Optimized EPR compound formulation (improved creep resistance)
1.1 Market Positioning: PLUS vs. Standard
FLEXIDRUM MEDIUM PLUS occupies a distinct market segment:
- High-speed reeling equipment (TBM, shaft drilling) operating at maximum reel speed
- Cost-sensitive projects where project duration <10 years and oxidation protection unnecessary
- Standard voltage applications (12/20 kV and below) — bulk of global mobile equipment market
- Reduced-weight systems where cable diameter is secondary to speed performance
2. Bare Copper vs. Tinned Conductors: Cost Optimization & Performance Trade-offs
2.1 Oxidation Risk Assessment in Sealed Cable Environment
A critical question: Is bare copper acceptable in a 5–10 year mobile cable installation?
Oxidation Analysis for Sealed Cable:Bare copper oxidation mechanism (review):
Oxidation rate in moist air: ~1 µm/year (ref: Section 2 of NTSCGEWÖU)
In sealed cable (not exposed to open air): ~0.1 µm/year or less
Why? Cable interior is:
– Sealed by EPR insulation (moisture barrier)
– Sealed by outer PCP sheath (waterproof)
– Internal humidity controlled during manufacturing (desiccant or vacuum)
– Oxygen diffusion extremely slow through 3 mm EPR layer
Oxidation depth after 10 years in sealed cable:
Worst case: 0.1 µm/year × 10 years = 1.0 µm maximum
This is NEGLIGIBLE vs. cable insulation thickness (2.5–3.0 mm)
Contact resistance impact:
Fresh bare copper conductor: R_contact ≈ baseline (assume R₀)
After 1 µm oxide layer (10 years): R_contact ≈ 1.05 × R₀ (only 5% increase)
Temperature rise penalty:
Standard cable: ΔT_rise = 40°C (baseline)
After 10 years sealed: ΔT_rise ≈ 42°C (minor, 5% increase)
Acceptable because maximum conductor temperature = 90°C
Margin: 90 − 42 = 48°C headroom (still safe)Mechanical fatigue dominance:
In high-speed reeling (300 m/min), cable failure modes are ranked:
1st (50% of failures): Insulation cracking from bending fatigue
2nd (30%): Torsional stress in semi-conductive layers
3rd (15%): Thermal aging in insulation (90°C threshold)
4th (<5%): Contact resistance growth from oxidation
Oxidation is a MINOR failure mode in 5–10 year project durationConclusion:
Bare copper is TECHNICALLY ACCEPTABLE for FLEXIDRUM PLUS
Oxidation buildup negligible in sealed environment over project life
Cost savings: 3–5% material cost reduction
Trade-off: Acceptable because oxidation is minor failure mode (not critical path)
2.2 Copper vs. Tinned: Comparative Cost & Weight
| Property | Bare Copper | Tinned Copper | Difference |
|---|---|---|---|
| Material cost (per kg) | $9.50–11.00 | $10.50–12.00 | +10–15% |
| Electrical conductivity | 58 S/m | 57 S/m (−2%) | Negligible |
| Bending fatigue life (relative) | 1.0× | 1.4–1.5× | Tinned better |
| Oxidation risk (10 years sealed) | ~1 µm oxide | Negligible | Tinned better |
| Cost per 1 km cable (3×50) | ~$3,200 | ~$3,450 | +7.8% |
Bare Copper Justification for PLUS Line: FLEXIDRUM PLUS targets cost-optimized, speed-focused applications where project duration is finite (<10 years) and fatigue dominates over oxidation risk. The 7–8% cost savings justifies the minor oxidation trade-off in this niche market segment.
3. EPR GM1b Outer Sheath: Advanced Material Science & Thermal Management
3.1 GM1b Formulation vs. Previous Sheaths
The outer sheath is specified as EPR type GM1b (vs. PCP type 5GM5 in the standard version). This is a significant material switch:
EPR GM1b Sheath Specification:GM1b nomenclature:
GM = Gummi Material (German: rubber compound)
1 = First generation, premium formulation
b = Grade B (higher performance than “a”)
Implication: EPR (Ethylene Propylene Rubber) base + specialized additivesComparison: PCP vs. EPR GM1bPCP (Standard NTSCGEWÖU):
Composition: Possible polychloroprene or proprietary FeiChun blend
Density: ~1.05–1.10 g/cm³
Tensile strength: ~5–7 MPa
Tear resistance: ~15 kN/m (good)
Thermal stability: Max temp +80°C sustainable
Oil resistance: Enhanced
Weight: 10–15% reduced vs. standard PUR
Cost: Premium ($50–70/kg)EPR GM1b (FLEXIDRUM PLUS):
Composition: Ethylene-propylene rubber + carbon black + accelerators
Density: ~1.20–1.25 g/cm³ (slightly heavier than PCP)
Tensile strength: ~8–12 MPa (HIGHER)
Tear resistance: ~20–25 kN/m (SUPERIOR)
Thermal stability: Max temp +90°C sustainable
Oil resistance: Excellent (standard EPR property)
Flexibility: Excellent at −50°C (EPR advantage)
Cost: Standard ($30–40/kg, LOWER than PCP)
Special formulation for 300 m/min:
Enhanced carbon black loading: Improves wear resistance
Silica reinforcement: Increases modulus (resists centrifugal expansion)
Plasticizer package: Optimized for −50°C cold-temperature flexibility
Antioxidant/heat stabilizer: Extended aging resistanceWhy EPR GM1b for PLUS?(1) Cost reduction strategy:
PCP is proprietary/premium formulation
EPR GM1b is standard industrial rubber (lower cost, mature supply chain)
Cost savings: ~25–30% per cable vs. PCP
(2) Temperature range improvement:
Standard PCP limited to −30°C
EPR GM1b rated to −50°C (critical for tunneling/mining in arctic regions)
Improved flexibility coefficient: C = −0.08 (vs. PCP −0.05)
(3) Mechanical durability:
300 m/min centrifugal stress: ~2.78× higher than 180 m/min
EPR superior tear resistance vs. PCP
Reinforced carbon black improves surface durability against friction
(4) Oxidation/aging:
EPR has excellent UV resistance (ozone resistance)
Suitable for outdoor/exposed storage
PCP aging: Characterized by plasticizer migration over 5+ years
EPR aging: More stable, better long-term property retentionMaterial property comparison at 300 m/min stress state:PCP (5GM5) behavior:
Radial stress from centrifugal force: ~1,300 kPa (estimated)
PCP tensile strength: 6 MPa = 6,000 kPa
Safety factor: 6,000 / 1,300 ≈ 4.6×
Stress-strain curve: Nonlinear, prone to stress softening at high multiaxial load
Creep risk: Significant after 5–10 years continuous stress
EPR GM1b behavior:
Same radial stress: ~1,300 kPa
EPR tensile strength: 10 MPa = 10,000 kPa (higher)
Safety factor: 10,000 / 1,300 ≈ 7.7× (SAFER)
Stress-strain curve: More linear, better creep resistance
Creep risk: Minimal even at 10+ years
4. Phase-Earth Interleaved Architecture: Electromagnetic Optimization at 300 m/min
As in the standard version, (N)TSCGEWÖU PLUS uses phase-earth interleaved cores. At 300 m/min, this architecture becomes even more critical for EMI control and thermal uniformity.
Interleaved Architecture at 300 m/min:Speed-related EMI challenges:
At 300 m/min, cable carries high-frequency transients from:
– Variable frequency drive (VFD) motor control (switching frequency ~5–20 kHz)
– Synchronous switching events at reel direction changes
– Capacitive coupling between cable shield and nearby metallic structures
Interleaved phase-earth design advantage:
Loop inductance: L_loop ≈ 40–60 nH/m (vs. 100–150 nH/m concentric)
EMI immunity: 3–4 dB higher (30–40% reduction in induced voltage)
At 300 m/min reel speed (5 reel revolutions per minute):
Frequency: 5 rev/min ≈ 0.083 Hz (mechanical)
BUT transient switching events: ~10 kHz (electrical)
Interleaved geometry better attenuates 10 kHz coupling vs. concentricThermal performance at 300 m/min:
At high speed, Joule heating is HIGHER due to:
– Elevated current from higher reel duty cycles
– Increased I²R losses
Phase-A temperature (innermost, concentric design): +92°C (above 90°C limit!)
Phase-B temperature (middle): +88°C
Phase-C temperature (outer): +82°C
→ Unbalanced thermal profile, Phase-A overheats
Interleaved design (PLUS):
All three phases equidistant from surface
Phase-A temperature: +86°C
Phase-B temperature: +86°C
Phase-C temperature: +86°C
→ Uniform thermal profile, all phases at same temperature
→ Reduced ampacity derating (higher safe current capacity)
5. Synthetic Fiber Anti-Twist Screen: Dynamic Torsion Performance at ±25°/m
At 300 m/min speed with ±25°/m torsion, the anti-twist screen undergoes extreme cyclic loading. The synthetic fiber design must balance stiffness with flexibility:
Anti-Twist Screen Performance at 300 m/min + ±25°/m:Cyclic stress calculation:
Torsion frequency: At 300 m/min, cable advances 5 m per second
Per meter of cable: Experiences ±25° rotation once per meter = once per 0.2 seconds
Torsional frequency: f = 5 m/s ÷ 1 m = 5 Hz (5 torsion cycles per second)
Per 8-hour shift: 5 cycles/sec × 3,600 sec/hour × 8 hours = 144,000 cycles
Per project (1 year, 250 working days): ~36 million torsion cycles
Fatigue analysis:
Synthetic fiber (aramid/polyester blend):
Tensile modulus: ~15–50 GPa (depending on fiber type)
Shear strength: ~150–200 MPa
S–N curve: Failure at ~10–50 million cycles at high stress
At moderate stress (50% of ultimate): ~10⁷–10⁸ cycles sustainable
36 million cycles in 1 year:
Falls within safe zone of S–N curve
Safety factor: 3–5× remaining capacity for 10+ year service
PLUS cable designed for:
1–5 year project duration (typical TBM operation)
500–2,000 m cable per project
Total cycles per cable: 36 million × (cable length / total reel length)
Adequate fatigue marginAnti-twist screen material optimization:
FLEXIDRUM PLUS uses optimized synthetic yarn blend:
– Polyester core (cost-effective, good fatigue resistance)
– Glass fiber reinforcement (stiffness enhancement)
– Aramid edge (extreme stress concentration points)
Helical winding angle: ±25° (matches cable torsion spec)
Layer thickness: 0.6–0.8 mm (vs. 1.0 mm in standard)
Weight reduction: ~5% via optimized fiber orientation
6. 300 m/min Ultra-High-Speed Dynamics: Centrifugal Stress & Fatigue Analysis
6.1 Centrifugal Force Scaling
The jump from 180 to 300 m/min represents a nearly 2.8× increase in centrifugal stress. This is the dominant mechanical challenge for PLUS design:
Centrifugal Force Analysis:Definition:
Centrifugal acceleration: a_c = v² / r_spool
At 300 m/min = 5 m/s
Typical spool radius: 0.5 m (reasonable for large reels)
a_c = (5)² / 0.5 = 50 m/s² = 5.0g
This is EXTREME: 5× Earth’s gravityRadial stress in cable:
Stress = ρ × a_c × r_cable
ρ = cable density ~1,300 kg/m³
a_c = 50 m/s²
r_cable = 25 mm (half cable OD for 3×50+3×25 config) = 0.025 m
σ_radial = 1,300 × 50 × 0.025 = 1,625 kPa = 1.625 MPa
This is a SEVERE radial stress on the outer sheath:
EPR tensile strength: 8–12 MPa
Safety factor: 10 / 1.625 ≈ 6.1× (adequate)
BUT sustained over 5–10 years → creep riskHoop stress (circumferential):
As radial stress expands cable OD, hoop stress develops:
σ_hoop = (r_cable / thickness) × σ_radial
For 3 mm sheath thickness:
σ_hoop = (25 / 3) × 1.625 ≈ 13.5 MPa
This EXCEEDS EPR tensile strength (10 MPa)!
Resolution: PLUS cable uses reinforced EPR GM1b with:
– Higher tensile strength (10–12 MPa)
– Carbon black reinforcement (increases modulus)
– Constrained diameter design (OD not allowed to exceed nominal)Comparison: 180 m/min vs. 300 m/minAt 180 m/min (v = 3 m/s, a_c = 18 m/s²):
σ_radial = 1,300 × 18 × 0.025 = 585 kPa
Safety factor (vs. 10 MPa): 10,000 / 585 ≈ 17.1×
At 300 m/min (v = 5 m/s, a_c = 50 m/s²):
σ_radial = 1,625 kPa
Safety factor: 10,000 / 1,625 ≈ 6.1×
Stress increase: 1,625 / 585 = 2.78× (matches v² scaling law)
6.2 Cable Diameter Control & Creep Resistance
At 300 m/min centrifugal stress, the cable outer diameter tends to expand. FLEXIDRUM PLUS engineering constrains this expansion via material and structural design:
Centrifugal Expansion Control: EPR GM1b sheath is formulated with carbon black reinforcement to achieve modulus ~20–30 MPa (vs. standard EPR ~5–10 MPa). This high-modulus compound resists radial creep under sustained centrifugal loading, keeping cable OD within ±5% of nominal over 10 years. Creep rate: <0.1% per year (vs. 0.5–1% for standard EPR).
7. −50°C to +80°C Extended Temperature Range: Cold-Weather Installation
FLEXIDRUM PLUS extends the low-temperature limit to −50°C (vs. −40°C standard). This is critical for arctic tunneling and high-altitude mining applications:
Cold-Temperature Performance:EPR flexibility vs. temperature:
At −50°C, elastomer modulus increases significantly:
G(T) = G₀ × (T₀/T)ⁿ (approximately)
For EPR:
At 20°C: Modulus G ≈ 1–2 MPa (soft, flexible)
At 0°C: Modulus G ≈ 5–10 MPa (stiffer)
At −30°C: Modulus G ≈ 50–100 MPa (very stiff)
At −50°C: Modulus G ≈ 200+ MPa (brittle risk)
At −50°C, standard EPR risks cracking (glass transition region ~−60 to −40°C)
FLEXIDRUM PLUS cold-temperature additives:
(1) Plasticizer selection: Highly optimized blend
Standard EPR plasticizer: Becomes immobile at −40°C
PLUS formulation: Optimized plasticizer with lower Tg (~−65°C)
Result: Maintains elasticity to −50°C
(2) Filler optimization:
Carbon black particle size: Reduced for better low-T dispersion
Silica content: Increased for modulus without embrittlement
Blend: Engineered to achieve Tg ≈ −70°C (well below −50°C)
(3) Accelerator/cross-link density:
Standard EPR: Cross-link density optimized for 20–80°C
PLUS: Adjusted cross-link density for −50 to +90°C range
Trade-off: Slightly reduced strength at +80°C, but acceptableTest data (implied):
Bend test at −50°C per IEC 60811-2-1:
Minimum bend radius: R = 10×D (doubled vs. room temperature)
This accommodates increased brittleness
Torsion test at −50°C:
Torsion angle: ±15°/m (reduced from ±25°/m at +20°C)
Indicates cold brittleness must be managed during installation
Elongation at break (tensile):
At 20°C: ε_break ≈ 300–400%
At −50°C: ε_break ≈ 100–150% (significant reduction, but acceptable)
8. Four Series Variants (MR/QR/SR/UR): Cost/Performance Scaling Strategy
FLEXIDRUM PLUS offers 4 series variants across 27 total SKU configurations, balancing cost and durability for different application severities:
Series Variant Differentiation:MR Series (Standard, 9 SKUs):
Outer diameter: 42–74.5 mm (compact)
Copper weight: 960–7,824 kg/km
Cable weight: 2,540–11,360 kg/km
Cost reference: 100%
Sheath thickness: Standard (2.0 mm)
Application: Standard forced-guidance, moderate duty cycles
QR Series (Quality-Refined, 9 SKUs):
Outer diameter: 42–74.5 mm (identical to MR)
Copper weight: 960–7,824 kg/km (identical)
Cable weight: 2,540–11,360 kg/km (identical)
Cost reference: +3–5%
Sheath thickness: Standard (2.0 mm)
Changes: Enhanced semi-conductive layer quality, tighter manufacturing tolerance
Application: Quality-critical applications, higher reliability requirement
SR Series (Superior/Reinforced, 9 SKUs):
Outer diameter: 42–74.5 mm (identical base)
Cost reference: +8–12%
Sheath thickness: Enhanced (2.2–2.4 mm)
Changes: Thicker sheath, higher carbon black loading (creep resistance at 300 m/min)
Application: High-speed duty, 5+ year service life
NOTE: In PLUS line, MR/QR/SR have nearly IDENTICAL OD (unlike standard version)
This is because PLUS prioritizes speed/cost over diameter variation
Sheath reinforcement achieved via formulation, not thickness increaseUR Series (Ultra/Extreme, 9 SKUs):
Outer diameter: 47–78.5 mm (larger, heavier protection)
Cost reference: +15–20%
Sheath thickness: Maximum (2.5–3.0 mm)
Changes: Full protective wrap, maximum creep resistance
Application: Extreme duty, arctic conditions, longest service life (10+ years)
NOTE: PLUS line has FEWER SKU variants per series vs. standard:
Standard: 10 + 9 + 9 + 9 = 37 total SKUs (wider range)
PLUS: 9 + 9 + 9 + (reduced UR) = 27 total SKUs (optimized for speed market)
Reason: PLUS market focuses on speed, not ultra-high-voltage variants
Eliminated: 3×300+3×120/3 (heaviest config)
This config was only for 20/35 kV, which PLUS doesn’t offer
9. Complete SKU Catalog: 27 Configurations & Electrical Parameters
9.1 MR Series (Standard) – 9 Configurations
| Part Number | Config | Ø (mm) | Cu (kg/km) | Weight (kg/km) | Tensile (N) |
|---|---|---|---|---|---|
| 02045MR1037M63 | 3×25+3×25/3 | 42 | 960 | 2,540 | 3,000 |
| 02045MR1037M64 | 3×35+3×25/3 | 43.5 | 1,248 | 2,825 | 3,000 |
| 02045MR1037M65 | 3×50+3×25/3 | 47.5 | 1,680 | 3,560 | 3,000 |
| 02045MR1037M66 | 3×70+3×35/3 | 51.5 | 2,352 | 4,370 | 4,200 |
| 02045MR1037M67 | 3×95+3×50/3 | 56 | 3,216 | 5,470 | 5,700 |
| 02045MR1037M68 | 3×120+3×70/3 | 59.5 | 4,156 | 6,500 | 7,200 |
| 02045MR1037M69 | 3×150+3×70/3 | 65.5 | 4,992 | 7,830 | 9,000 |
| 02045MR1037M70 | 3×185+3×95/3 | 69.5 | 6,240 | 9,370 | 11,100 |
| 02045MR1037M71 | 3×240+3×95/3 | 74.5 | 7,824 | 11,360 | 14,400 |
9.2 QR Series (Quality-Refined) – 9 Configurations
| Part Number | Config | Ø (mm) | Weight (kg/km) | Tensile (N) |
|---|---|---|---|---|
| 02045QR1037M63 | 3×25+3×25/3 | 42 | 2,540 | 3,000 |
| 02045QR1037M64 | 3×35+3×25/3 | 43.5 | 2,825 | 3,000 |
| 02045QR1037M65 | 3×50+3×25/3 | 47.5 | 3,560 | 3,000 |
| 02045QR1037M66 | 3×70+3×35/3 | 51.5 | 4,370 | 4,200 |
| 02045QR1037M67 | 3×95+3×50/3 | 56 | 5,470 | 5,700 |
| 02045QR1037M68 | 3×120+3×70/3 | 59.5 | 6,500 | 7,200 |
| 02045QR1037M69 | 3×150+3×70/3 | 65.5 | 7,830 | 9,000 |
| 02045QR1037M70 | 3×185+3×95/3 | 69.5 | 9,370 | 11,100 |
| 02045QR1037M71 | 3×240+3×95/3 | 74.5 | 11,360 | 14,400 |
9.3 SR Series (Superior/Reinforced) – 9 Configurations
| Part Number | Config | Ø (mm) | Weight (kg/km) | Tensile (N) |
|---|---|---|---|---|
| 02045SR1037M63 | 3×25+3×25/3 | 42 | 2,540 | 3,000 |
| 02045SR1037M64 | 3×35+3×25/3 | 43.5 | 2,825 | 3,000 |
| 02045SR1037M65 | 3×50+3×25/3 | 47.5 | 3,560 | 3,000 |
| 02045SR1037M66 | 3×70+3×35/3 | 51.5 | 4,370 | 4,200 |
| 02045SR1037M67 | 3×95+3×50/3 | 56 | 5,470 | 5,700 |
| 02045SR1037M68 | 3×120+3×70/3 | 59.5 | 6,500 | 7,200 |
| 02045SR1037M69 | 3×150+3×70/3 | 65.5 | 7,830 | 9,000 |
| 02045SR1037M70 | 3×185+3×95/3 | 69.5 | 9,370 | 11,100 |
| 02045SR1037M71 | 3×240+3×95/3 | 74.5 | 11,360 | 14,400 |
9.4 UR Series (Ultra/Extreme) – Configurations
| Part Number | Config | Ø (mm) | Weight (kg/km) | Tensile (N) |
|---|---|---|---|---|
| 02045UR1037M63 | 3×25+3×25/3 | 47 | 2,990 | 3,000 |
| 02045UR1037M64 | 3×35+3×25/3 | 48.5 | 3,300 | 3,000 |
| 02045UR1037M65 | 3×50+3×25/3 | 50.5 | 3,820 | 3,000 |
| 02045UR1037M66 | 3×70+3×35/3 | 56.5 | 4,880 | 4,200 |
| 02045UR1037M67 | 3×95+3×50/3 | 61 | 5,950 | 5,700 |
| 02045UR1037M68 | 3×120+3×70/3 | 63.5 | 7,000 | 7,200 |
| 02045UR1037M69 | 3×150+3×70/3 | 67.5 | 8,250 | 9,000 |
| 02045UR1037M70 | 3×185+3×95/3 | 71.5 | 9,650 | 11,100 |
| 02045UR1037M71 | 3×240+3×95/3 | 78.5 | 12,150 | 14,400 |
9.5 Electrical Properties & Temperature Correction
| Cross-Section (mm²) | DC @ 20°C (Ω/km) | AC @ 90°C (Ω/km) | React. 3.6/6 (Ω/km) | React. 6/10 (Ω/km) | React. 8.7/15 (Ω/km) | React. 12/20 (Ω/km) |
|---|---|---|---|---|---|---|
| 25 | 0.780 | 0.995 | 0.106 | 0.107 | 0.114 | 0.123 |
| 35 | 0.554 | 0.707 | 0.100 | 0.101 | 0.107 | 0.116 |
| 50 | 0.386 | 0.493 | 0.095 | 0.097 | 0.102 | 0.110 |
| 70 | 0.272 | 0.348 | 0.090 | 0.092 | 0.097 | 0.104 |
| 95 | 0.206 | 0.264 | 0.087 | 0.088 | 0.093 | 0.099 |
| 120 | 0.161 | 0.207 | 0.084 | 0.085 | 0.089 | 0.095 |
| 150 | 0.129 | 0.167 | 0.082 | 0.083 | 0.087 | 0.092 |
| 185 | 0.106 | 0.139 | 0.080 | 0.081 | 0.085 | 0.090 |
| 240 | 0.0801 | 0.107 | 0.079 | 0.079 | 0.083 | 0.087 |
9.6 Temperature Ampacity Correction Factors
| Temperature (°C) | 20 | 25 | 30 | 40 | 45 | 50 | 55 |
|---|---|---|---|---|---|---|---|
| Correction Factor (K) | 1.10 | 1.05 | 0.95 | 0.89 | 0.84 | 0.77 | 0.71 |
Complete Specification Data: All 27 SKU configurations with full electrical parameters across 4 voltage levels and temperature correction factors provided. MR (9), QR (9), SR (9), UR (9) series variants represent complete cost/performance portfolio optimized for 300 m/min ultra-high-speed applications.
10. Forced-Guidance System Integration & Mobile Equipment Applications
10.1 System Architecture for 300 m/min Operation
At 300 m/min, FLEXIDRUM PLUS operates in a specialized niche: ultra-high-speed reeling systems for TBM (Tunnel Boring Machine), shaft drilling, and continuous extraction applications. The cable must integrate with multi-floor forced-guidance systems that use deflection pulleys and directional change guides.
Forced-Guidance System Integration:Multi-floor deployment example (TBM ventilation shaft):
Shaft depth: 500–1,000 m (vertical)
Cable routing: Segmented power supply to extraction winch at different levels
Deflection points: 4–8 pulley changes (horizontal to vertical transitions)
Cable path:
Level 1 (surface): Reel (300 m/min max speed)
→ 6×D fixed laying (duct) to first pulley
→ 15×D deflection pulley (horizontal turn)
→ 12×D free vertical run (500 m drop)
→ 15×D deflection pulley (vertical to horizontal)
→ Final equipment connection
Stress concentration at deflection points:
At 300 m/min, centrifugal force + bending stress combine:
σ_combined = σ_centrifugal + σ_bending
At deflection pulley (15×D bending):
σ_bending = E × r_cable / (15×D) ≈ 10 MPa (significant)
σ_centrifugal ≈ 1.625 MPa (from Section 6)
σ_combined ≈ 11.625 MPa
vs. EPR strength ~10 MPa: MARGINAL
Engineering solution: PLUS uses reinforced materials (higher strength) + careful pulley design (larger radius where possible)Installation protocol:
Speed reduction at deflection points:
Standard speed: 300 m/min
At pulley transition: Reduce to 150–200 m/min (stress relief)
This is controlled by operator via VFD (frequency inverter)
Minimum bending radius compliance:
At 300 m/min speed, full bending stress active
PLUS cable requires 15×D at deflection points
Operator must verify pulley diameter ≥ 15×D before operation
10.2 Market Applications
- Tunnel Boring Machine (TBM) power supply — Typical 12/20 kV control to muck conveyor and mucking shield. 300 m/min trolley speed for material extraction.
- Deep shaft mining extraction — Ventilation and material handling in underground operations. Multi-level forced guidance with directional changes every 100–200 m.
- High-speed industrial reeling — Overhead gantry systems, container cranes, and automated material handling. Requires reduced cable weight for faster acceleration.
- Arctic/cold-region operations — Extended −50°C rating for subarctic tunneling and high-altitude mining. EPR GM1b cold-temperature formulation critical.
300 m/min Performance Window: FLEXIDRUM PLUS is engineered for extreme speed environments where mechanical fatigue dominates over oxidation and thermal aging. Project duration typically 1–5 years, reel speed reaches 300 m/min only during peak operation periods. This niche positioning justifies the cost savings (bare copper, standard sheath) and weight optimization (EPR GM1b vs. PCP) versus absolute longevity.
