1. Introduction引言

In underground coal mines operating room-and-pillar extraction, shuttle cars are the primary batch haulage vehicles that ferry coal from the continuous miner face to the feeder-breaker. These electrically powered vehicles — typically operating at 550–1,000 V AC — depend on a flexible trailing cable that is continuously reeled and unreeled as the shuttle car trams distances of up to 150 m or more. Cable damage from runovers, corkscrewing, and abrasion represents one of the largest sources of unplanned downtime in underground coal operations. 在采用房柱法开采的井下煤矿中，穿梭车是将煤从连续采煤机工作面运至给煤破碎机的主要间歇式运输车辆。这些电动车辆通常在 550–1,000 V AC 下运行，依靠柔性拖曳电缆在长达 150 m 或更远的距离内持续收放。电缆被碾压、扭结（corkscrewing）和磨损造成的损坏是井下煤矿非计划停机的最大来源之一。

This article provides a detailed technical comparison between two cable approaches for shuttle car duty: the AS/NZS 1802 Type 241 — a widely used general-purpose trailing cable for underground coal mines — and the Nexans TENIO® concept, a lightweight, optimised trailing cable design from Nexans’ mining portfolio that targets reduced cable weight and improved reeling behaviour for shuttle car applications. 本文对穿梭车用途的两种电缆方案进行了详细技术对比：AS/NZS 1802 Type 241——广泛用于井下煤矿的通用拖曳电缆；以及 Nexans TENIO®——Nexans 矿用电缆系列中面向穿梭车应用的轻量化、优化拖曳电缆设计。

2. Why Shuttle Cars Push Cables to Their Limits穿梭车为何将电缆推向极限

Shuttle cars subject their trailing cables to the most extreme mechanical conditions encountered underground. The cable is reeled at high speed (often 2–3 m/s), wound under tension onto an onboard reel, dragged across rough floor, and frequently run over by the vehicle itself or by adjacent shuttle cars sharing the same panel. According to Prysmian’s technical documentation, shuttle car cables “are subject to the greatest exertion underground” and must incorporate anti-corkscrewing construction to survive repeated high-speed reeling cycles. 穿梭车使其拖曳电缆承受井下最极端的机械条件。电缆以高速（通常 2–3 m/s）收卷，在张力下缠绕到车载卷筒上，在粗糙地面上拖拽，并频繁被本车或共享同一工作面的相邻穿梭车碾压。根据 Prysmian 的技术文档，穿梭车电缆”承受井下最大的外力”，必须采用防扭结构以在反复高速收放循环中存活。

The core cable challenges unique to shuttle car duty include: simultaneous tensile and torsional loading during high-speed reel-in; exposure to coal dust, water, and acidic mine drainage; risk of runover by 20+ tonne machines; flame-retardancy requirements in methane-rich atmospheres per MSHA 30 CFR Part 18.64 or AS/NZS 1802; and the need for earth-fault screening (electrically symmetrical construction) to prevent ignition of explosive atmospheres. 穿梭车工况特有的电缆核心挑战包括：高速回收时同时承受拉伸和扭转载荷；暴露于煤尘、水和酸性矿井排水中；被 20 吨以上设备碾压的风险；根据 MSHA 30 CFR Part 18.64 或 AS/NZS 1802 在富含甲烷的环境中的阻燃要求；以及防止引爆爆炸性气氛所需的接地故障屏蔽（电气对称结构）。

3. What Is Type 241?何为 Type 241？

Type 241 is a general-purpose trailing cable defined under AS/NZS 1802:2018, the Australian/New Zealand standard for elastomer-insulated reeling and trailing cables in underground coal mines. It features semiconductive-screened power cores, three interstitial earth cores, one central pilot, and a heavy-duty elastomer outer sheath. The cable is available in voltage ratings from 1.1/1.1 kV to 11/11 kV. Type 241 是根据 AS/NZS 1802:2018（澳大利亚/新西兰井下煤矿弹性体绝缘卷缆和拖缆标准）定义的通用拖曳电缆。其特征包括半导电屏蔽电力芯线、三根间隙接地芯线、一根中心导引线和重型弹性体外护套。电压等级从 1.1/1.1 kV 到 11/11 kV 不等。

Notably, cable manufacturer Üntel’s published datasheet describes Type 241 as a “general use cable for underground coal mines (except for shuttle cars),” highlighting that the standard Type 241 construction is considered sub-optimal for shuttle car reeling duty. For shuttle car applications specifically, the AS/NZS 1802 standard provides Type 275 — a cable with enhanced anti-corkscrewing features and earth cores specifically designed to resist wire breaks during reeling under tension. 值得注意的是，电缆制造商 Üntel 发布的数据手册将 Type 241 描述为”井下煤矿通用电缆（穿梭车除外）“，说明标准 Type 241 结构被认为对穿梭车卷绕工况并非最优。针对穿梭车应用，AS/NZS 1802 标准专门提供了 Type 275——一种具有增强防扭结特性和专门设计以抵抗张力卷绕时断丝的接地芯线的电缆。

4. What Is Nexans TENIO®?何为 Nexans TENIO®？

The Nexans TENIO® represents a lightweight trailing cable design within Nexans’ comprehensive POWERMINE® mining cable portfolio. Nexans — through its subsidiaries including AmerCable (Tiger® Brand) and Olex — is one of the world’s largest producers of mining trailing and reeling cables. The TENIO® concept targets weight reduction and improved flexibility for shuttle car and similar high-cycle trailing applications, while retaining the full safety and screening requirements of underground coal mine standards. Nexans TENIO® 是 Nexans 综合性 POWERMINE® 矿用电缆系列中的一种轻量化拖曳电缆设计。Nexans 通过其子公司 AmerCable（Tiger® Brand）和 Olex，是全球最大的矿用拖缆和卷缆生产商之一。TENIO® 概念旨在为穿梭车等高循环拖曳应用实现减重和提升柔韧性，同时保留井下煤矿标准所要求的全部安全和屏蔽性能。

Key design philosophy behind TENIO®-class lightweight trailing cables includes: optimised conductor lay to reduce overall cable diameter; advanced EPR insulation compounds achieving equivalent dielectric strength at reduced radial thickness; reinforced-yet-lighter outer sheath compounds; and reduced weight per metre that directly translates to lower drag force on the shuttle car reeling system, less cable damage from runovers, and easier manual handling during splicing or replacement. TENIO® 级轻量化拖曳电缆的核心设计理念包括：优化导体绞合以减小电缆总直径；先进的 EPR 绝缘配方在更薄的径向厚度下实现等效介电强度；增强但更轻的外护套配方；以及每米重量的降低——直接转化为穿梭车卷缆系统上更低的拖拽力、碾压时更少的电缆损坏以及接头或更换时更便捷的人工操作。

5. Governing Standards & Compliance执行标准与合规

Both cable types must satisfy the fundamental safety requirements of AS/NZS 1802:2018 — electrical symmetry for AC supply and earth-fault screening — which are essential in underground coal mines due to methane explosion risk. The standard also mandates specific tests for insulation earth-screen volume resistivity and limits maximum sheath thickness to 9.0 mm to control overall cable dimensions. 两种电缆类型都必须满足 AS/NZS 1802:2018 的基本安全要求——交流供电的电气对称性和接地故障屏蔽——这在井下煤矿中因甲烷爆炸风险而至关重要。该标准还规定了绝缘接地屏蔽体积电阻率的专项试验，并将最大护套厚度限制在 9.0 mm 以控制电缆总外径。

6. Construction Comparison结构对比

The critical structural differences lie in two areas. First, the TENIO® lightweight concept uses an aramid-reinforced braid (similar to the Kevlar® braid used in Type 275 shuttle car cables as documented by Prysmian) rather than a standard open-weave textile braid. Aramid fibres deliver dramatically higher cut-through and tear resistance at lower weight — a crucial advantage for cables that are routinely dragged across broken rock and coal debris. Second, the outer sheath uses an HD-85-PCP (heavy-duty 85-shore polychloroprene) compound that is thinner yet maintains equivalent abrasion resistance, contributing to the overall weight reduction. 关键的结构差异体现在两个方面。第一，TENIO® 轻量化概念采用芳纶增强编织层（类似于 Prysmian 记录的 Type 275 穿梭车电缆中使用的 Kevlar® 编织层），而非标准的开放式纺织编织。芳纶纤维以更轻的重量提供了显著更高的抗切割和抗撕裂性能——对于经常在碎岩和煤屑上拖拽的电缆来说，这是至关重要的优势。第二，外护套采用更薄但保持同等耐磨性的 HD-85-PCP（重型 85 邵氏硬度氯丁橡胶）配方，有助于整体减重。

7. Electrical Parameters电气参数

Electrically, both cable types are virtually identical — they must satisfy the same AS/NZS 1802 requirements for insulation performance, earth-screen resistivity, and electrical symmetry. The innovation in the TENIO® design is mechanical and dimensional rather than electrical: by reducing cable OD and weight without compromising dielectric performance, the cable creates less drag resistance on the reel, which in turn reduces the peak tensile load experienced during each reeling cycle — indirectly extending insulation life by reducing cumulative mechanical fatigue. 电气性能上，两种电缆几乎相同——它们必须满足相同的 AS/NZS 1802 绝缘性能、接地屏蔽电阻率和电气对称性要求。TENIO® 设计的创新在机械和尺寸层面而非电气层面：通过在不影响介电性能的前提下减小电缆外径和重量，电缆在卷筒上产生更小的拖拽阻力，从而降低每次卷绕循环中的峰值拉伸载荷——间接地通过减少累积机械疲劳来延长绝缘寿命。

8. Mechanical & Environmental Performance机械与环境性能

The mechanical divergence is significant. Type 241 — as documented by Üntel and Eland Cables — is a versatile cable serving continuous miners, pump feeders, monorail supply, and longwall gate-end applications, but it lacks the purpose-built anti-corkscrewing features needed for shuttle car duty. In contrast, the TENIO® concept (and the comparable AS/NZS 1802 Type 275) incorporates carefully engineered conductor lay angles, balanced core tensions, and reinforced sheath design that distribute torsional stresses evenly — preventing the asymmetric deformation that leads to catastrophic failure during high-speed reeling. 机械性能差异显著。如 Üntel 和 Eland Cables 所记录，Type 241 是一种服务于连续采煤机、泵送给电、单轨供电和长壁工作面机尾等应用的多用途电缆，但缺乏穿梭车工况所需的专用防扭结特性。相比之下，TENIO® 概念（以及对标的 AS/NZS 1802 Type 275）融入了精心设计的导体绞合角度、平衡芯线张力和增强护套设计，均匀分配扭转应力——防止高速卷绕时导致灾难性失效的不对称变形。

9. Weight & Handling Advantages重量与操作优势

A 15–20% reduction in cable weight per metre may appear modest, but across a 150 m trailing cable deployment on a shuttle car, this equates to roughly 150–225 kg less cable mass being reeled, dragged, and managed. This directly reduces the energy consumed by the cable reel motor, lowers peak tensile stress at the cable entry point, and reduces the severity of damage when the cable is run over — since a smaller-diameter cable is deflected more easily rather than being crushed flat. 每米减重 15–20% 看似不大，但以穿梭车上 150 m 拖曳电缆部署计算，这意味着需要卷绕、拖拽和管理的电缆质量减少约 150–225 kg。这直接降低了卷缆电机的能耗，降低电缆入口处的峰值拉伸应力，并减轻电缆被碾压时的损伤严重程度——因为较小直径的电缆更容易被偏转而非被压扁。

10. Total Cost of Ownership全寿命周期成本分析

In underground coal mining, Nexans AmerCable has reported that trailing cable downtime for shovels alone costs approximately USD 30,000 per hour. While shuttle car downtime costs are lower per unit, the cumulative impact across a multi-car section operating two 10-hour production shifts daily is substantial. Using a cable that lasts 2–3× longer in the reeling application more than compensates for the 10–18% procurement premium. 在井下煤矿中，Nexans AmerCable 报告称仅电铲的拖曳电缆停机成本就约为每小时 30,000 美元。虽然单台穿梭车停机成本较低，但在一个每天运行两个 10 小时生产班次的多车工作面中，累积影响相当可观。使用在卷绕应用中寿命延长 2–3 倍的电缆，足以补偿 10–18% 的采购溢价。

11. Feichun’s Equivalent Solution飞纯的同等方案

Anhui Feichun Special Cable Co., Ltd. (安徽飞纯特种电缆有限公司) manufactures lightweight trailing cables for shuttle car and continuous miner applications that are engineered to match the performance envelope of both Type 241 and Type 275 under AS/NZS 1802:2018. Our cables feature Class 5 fine-stranded tinned copper conductors, R-EP-90 EPR insulation per AS/NZS 3808, semiconductive screening, interstitial earth conductors with semiconductive covering, and heavy-duty elastomer outer sheaths with optional aramid-reinforced braid for enhanced anti-corkscrewing performance. 安徽飞纯特种电缆有限公司为穿梭车和连续采煤机应用制造轻量化拖曳电缆，其性能设计与 AS/NZS 1802:2018 下的 Type 241 和 Type 275 相匹配。我们的电缆采用 Class 5 细绞镀锡铜导体、符合 AS/NZS 3808 的 R-EP-90 EPR 绝缘、半导电屏蔽、带半导电覆盖层的间隙接地导体，以及可选配芳纶增强编织层以增强防扭结性能的重型弹性体外护套。

All production batches undergo rigorous testing: high-voltage withstand (4.2 kV AC for 1.1 kV cables), insulation resistance (≥ 50 MΩ·km), conductor resistance per IEC 60228 Class 5, and flame retardancy per AS/NZS 1802 requirements. By sourcing directly from Feichun, mine operators gain access to competitive pricing, flexible MOQ, and engineering support for custom configurations — including cables matched to specific shuttle car reel dimensions and tramming distances. 所有生产批次均接受严格测试：高压耐受（1.1 kV 电缆为 4.2 kV AC）、绝缘电阻（≥ 50 MΩ·km）、符合 IEC 60228 Class 5 的导体电阻，以及符合 AS/NZS 1802 要求的阻燃性。通过直接从飞纯采购，矿方可获得有竞争力的价格、灵活的最小订购量和工程支持——包括针对特定穿梭车卷筒尺寸和行驶距离定制的电缆。

12. Conclusion总结

The AS/NZS 1802 Type 241 remains a proven, cost-effective trailing cable for general underground coal mine duty — powering continuous miners, pumps, and monorail systems. However, for the specific demands of shuttle car reeling, where high-speed winding, torsional stress, and runover exposure converge, a lightweight, purpose-built cable like the Nexans TENIO® (or the comparable Type 275 class) is the technically superior choice. The reduced weight, improved anti-corkscrewing construction, and aramid-reinforced sheath deliver measurably longer service life and lower total cost of ownership. AS/NZS 1802 Type 241 仍是井下煤矿通用拖曳工况——连续采煤机、水泵和单轨供电——经过验证的经济型电缆。但对于穿梭车卷绕这一高速缠绕、扭转应力和碾压风险汇聚的特殊工况，Nexans TENIO®（或同类的 Type 275 级别）这样的轻量化专用电缆才是技术上更优的选择。其减轻的重量、改进的防扭结结构和芳纶增强护套可提供可量化的更长使用寿命和更低的全寿命成本。

Anhui Feichun Special Cable manufactures AS/NZS 1802-compliant trailing cables in both standard and lightweight configurations, giving mine operators the freedom to match cable design precisely to application severity. Contact us for engineering consultation, datasheets, or competitive quotations. 安徽飞纯特种电缆同时生产标准型和轻量化配置的 AS/NZS 1802 拖曳电缆，让矿方能够精确匹配电缆设计与应用严苛程度。欢迎联系我们获取工程咨询、数据手册或竞争性报价。