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Introduction

This article will take an in-depth look at cable reels.

The article will bring more detail on topics such as:

  • Principle of Cable Reels
  • Types of Cable Reels
  • Applications and Benefits of Cable Reels
  • And Much More…
Shuttering Plywood Cable Reel

Chapter 1: Principle of Cable Reels

This chapter will discuss what cable reels are, their configuration, characteristics, and considerations when choosing cable reels.

What are Cable Reels?

Cable reels hold conductive cable or lifting cable and are used for storage, unwinding, and winding. Contacts on electric cable reels keep the power on while winding. Reels are machines that wrap long, continuous goods like cable, wires, paper, and other materials for transport or storage. Simple storage systems such as reels are available, while more advanced versions are self-winding. They can also be ordered with live connections, allowing you to utilize a hose or electrical wire while still on the reel.

Cable Reel

There are various ways to rewind cable reels. Manual or crank, electric, hydraulic, pneumatic, and spring are some of the options.

  • There is no rewind mechanism associated with a manual or crank rewind reel. Rewinding the hose or cable requires the use of a hand crank or another manual means.
  • Rewind reels are powered by a motor that rewinds the reel in electric, hydraulic, and pneumatic versions.
  • An internal spring is used to rewind the wheel on a spring rewind reel.

Configuration of Cable Reels

There are five main arrangements for cable reels. Collapsible, portable, live connection, reel and cable assembly, and storage reel are some of the options.

  • Collapsible reels can be collapsed or broken down for bulk shipping or compact storage.
  • Portable reels can be moved by hand. A lifting handle is included in the package.
  • Connection hardware is installed on live connection reels to allow electricity to pass through while the cable is still on or partially on, the reel.
  • A reel assembly consists of a reel, a wire, and any features that may be installed on the cable. One electrical cord on a reel with a light connected is an example.
  • A storage reel transports items other than cable or hose, such as paper or plastic.
Configuration of Cable Reels

Characteristics of Cable Reels

Flange diameter, core diameter, inside traverse, the outer diameter of the cable to be carried on the reel, and the length of the cable to be carried on the reel are all important characteristics of cable reels.

  • The outside diameter of the reel flange is known as the flange diameter.
  • The inside diameter of the reel or core is known as the core diameter.
  • The inside traverse is the distance between reel flanges on the inside.
Cable Reel

Considerations When Choosing Cable Reels

The considerations when selecting cable reels include:

  • Speed - Workers can run cable fast and effortlessly with the help of rollers. They set up in seconds rather than minutes, offering instant payments from high-capacity reels where they're most needed.
  • Safety - Roller systems alleviate fatigue and promote correct ergonomics by guaranteeing that each draw results in a consistent length of cable, regardless of the weight of the spool or other circumstances. Rollers are far safer than reel jack stands when utilized with optional tie-down kits.
    Safety of Cable Reels

  • Spool Protection - Spools can move freely on rollers, eliminating the risk of cable damage during payout.
  • Length of Cable – Cable reels come in different sizes depending on the cable length that is going to be installed on the drum of the cable reel.
  • What are the mechanical requirements for the reel? Is it better to stretch, raise, drag, or retrieve? In what kind of setting will the reel be placed? (Hazardous environment, inside, outdoors). What does the duty-cycle entail? What is the frequency of the reel payouts and retractions? What is the equipment's maximum speed? The maximum speed that is recommended is 150 feet per minute.
  • Electrical Requirements: How much amperage is expected to be carried by the cable? What is the voltage? What kind of signals will the reel have to handle: power, control, or communication? It is best to use a single conductor for dedicated ground. What is the required cable gauge (AWG)? The gauge will be determined by the amperage and total number of wires required.
  • Requirements for Cable Length:

    • ADD: Active Length: The difference between the lowest operating payout and the maximum operational payout.
    • PLUS: Inactive Length: Cable that remains out of the reel at all times, even when fully retracted.
    • PLUS: Safety Wrap: At maximum payment, the cable stays on the reel.
    • PLUS: Sag Factor – (Stretch Only): Add 10% to the total length of Active and Inactive.
    • The gap between where the cable lays up and the spool center line is known as the lift height (Drag/Retrieve). Maximum height is 4'.
    • Spool Ends – 2-3' Hook-up Length: Cable required for termination at both ends.
Moisture Resistant Cable Reel

Chapter 2: Types of Cable Reels

The different types of cable reels include:

Wooden Cable Reels

As the name suggests, wooden cable reels are made from wood. Wooden cable reels are used in applications where heavy loads are to be carried. The wooden reels can be used to reel in wires, ropes, and electrical cables. Depending on the product to be transported, they can be tailored to a variety of traverse lengths and flange diameters.

Wooden Cable Reel

The flanges are made first. The circular portions on either end of the core are the flanges. Two layers of lumber are attached perpendicular to each other, making one solid piece, to make a square flange. The square flange is cut into a circular shape with a bandsaw, which removes the edges. The circular flange is next rubbed to ensure a flat surface along the freshly cut edges.

Second, the flanges are tailored to the needs of the user. The diameters of the start hole and arbor hole, the number of bolt holes, and the angles of numerous holes are all common adjustments.

Third, the staves for the reel's core are formed from lumber. Because the core, also known as the drum, must form a circular, straight-edged lumber and must be rounded before being employed in this operation. Regular lumber is fed into a machine that shaves the edges off and produces a curved board known as a stave that will be used in the reel's drum. The flanges and staves are finally bolted together.

Plywood Cable Reels

The logs are soaked and heated to soften the wood before the veneers can be cut into suitable shapes and sizes. Depending on the type of wood, this procedure can take anywhere from 12 to 40 hours. The treated logs are put one at a time onto a peeler lathe, where they are fed to a full-length knife blade. This reduces the block's diameter to about 3 to 4 inches, and any remaining wood is removed from the lathe and replaced with a fresh log. Following that, the veneer is cut into usable widths in accordance with industry standards for plywood sheets.

The veneer is frequently arranged according to its grade. This can be done by hand or with the use of optical scanners. To reduce the moisture content of the wood and shrink the veneer's size, it is stored in a low-humid area known as a dryer. The necessary portions of the veneer are then assembled using a waterproof adhesive. Normally, this is done manually. The plywood is then transferred to a hot press, which can handle roughly 20 to 40 sheets at a time, after the glue has been properly applied to the sheets. Extreme temperature and pressure values of roughly 200 psi and 310 °F are created by the hot press. This ensures proper contact between the veneer layers and allows the adhesive to perform to its full potential.

Plywood Cable Reel

After that, the sheets are trimmed to precise widths and lengths using a series of precision saws. The grade, mill number, and other relevant information are stamped on the final plywood sheets. The cable reels can either be made from marine or shuttering plywood.

The characteristics of plywood include:

  • High panel shear - To maximize bending resistance, plywood is commonly made with an odd number of layers. The angle at which the veneer grains are stacked can be adjusted between 90 degrees and 180 degrees. Angles of 45 and 30 degrees to each other are common. The changes in angle strengthen the plywood. This enables the plywood to be used in constructed beams and bracing panels.
  • High Strength - Plywood has only as much strength as the tree it is made from. It can, however, be strengthened later in the production process. To prevent splitting, it is typical to put grains of each veneer at 90 degrees to each other, especially when hammered at the edges. The veneer gains additional strength and stability as a result of this.
  • Moisture Resistant - Several types of glue are utilized to join the veneer pieces together. The suitable adhesive gives the plywood particular features like moisture and humidity resistance. Water resistance is also improved by applying a layer of varnish and paint. The veneer can now be utilized for shelters, marine buildings, and cladding. Interior applications, such as floors and walls, benefit from moisture resistance as well. The veneers will not shrink or expand when exposed to high temperatures and water if the plywood is cross-laminated.
  • Resistance to Shock - Plywood is naturally resistant to impact and stress due to its high tensile strength, however cross lamination of veneers can further strengthen it. This is due to the force being distributed over a broad surface area, which reduces the tensile strength in isolated areas. The result is plywood that can endure up to three times its original load before disintegrating. This is especially handy when there are strong winds or earthquakes. Heavy-duty applications, such as concrete structure and flooring, call for plywood with high tensile strength.
  • Resistant to Fire - Despite the fact that plywood and veneer are known to be fire dangers, manufacturers have improved fire resistance by applying a chemical coating. Non-combustible compounds like fiber cement and plasterboard are used to achieve this. It can then be utilized to make structures conform to local requirements.
  • Insulation - Plywood offers a high level of sound and thermal insulation by nature. Insulation for floors, roofs, wall claddings, and ceilings is prevalent. Plywood's great insulating capabilities help you save money on heating and cooling over time.
  • Flexibility - Plywood also has the advantage of being formed to the maker’s specifications. It comes in a variety of thicknesses ranging from a few millimeters to many inches. Manufacturers use additional veneers to strengthen the plywood's strength. Each layer of veneer adds to the plywood's strength in a proportional way.

Marine Plywood

Although the name implies that marine plywood is naturally water-resistant, this is not the case. If it hasn't been treated with any chemicals, it's vulnerable to water damage. Marine plywood, on the other hand, is made of high-quality hardwood and adhered to the surface using waterproof adhesive.

You'll get robust, lightweight plywood that's defect-free if you choose higher quality grades. These characteristics make marine plywood an excellent choice for use in areas where there is water for example on ships. Marine plywood reels can be recycled into robust outdoor furniture, making the finished product more suitable for usage in coastal areas after being treated with a strong protective finish. The following grades of marine plywood are available: A, A-B, B, high density overlay, and medium density overlay.

Marine Plywood Cable Reel

Shuttering Plywood Cable Reel

Shuttering plywood is made of thick hardwood with a smooth film coating on both sides. It's mostly employed around building projects. Shuttering plywood is so dense that it includes at least nine layers of densely packed core veneers that are pressed together by high-pressure devices at extremely high temperatures. The ultimate product is plywood with a density of 750kg per cubic meter and a thickness of 12mm that is extremely robust. Shuttering plywood is used for heavy-duty applications where it must endure large loads.

Plastic Cable Reels

For monofilament and insulated wire makers, plastic reels are a sturdy and lightweight alternative packaging solution. Plastic reels can be recycled completely. Makers of industrial and residential wire, with uses for electrical wiring and data transmission cables, manufacturers of ribbon and tape, and monofilament manufacturers for recreational and medicinal applications are among the current applications.

Plastic Cable Reels

The diameter of plastic flanges ranges from 6 12" to 24". The plastic flanges can also be customized to any size. Plastic reels can be manufactured at home as long as a 3D printer is available. The benefit is that the total weight is significantly reduced. They are the only cable caps that are suited for medical technology's stringent health and cleanliness requirements.

Steel Cable Reels

Steel drums have largely replaced traditional wooden drums in the cable and wire business, particularly in the offshore sector. Steel drums are usually welded as fixed drums, however there are also collapsible steel drums. Steel reels or drums are made in an environmentally responsible manner and are more durable than wooden drums, although at a much greater price. Steel reels are more difficult to steal. Steel reels or drums are chosen by the offshore business nowadays over hardwood, plywood, or plastic reels or drums, although the previous land-based industry favored wooden drums due to reduced costs. Steel reels can be loaded with a variety of cables and wires, ranging from the heaviest to the lightest. These steel coils are more durable than wooden coils and are made in an environmentally sustainable manner. Cable drums that are spring loaded and can be mounted in various ways. These cable retractors, also known as spring coils, are a quick and cost-effective option for applications requiring counterbalance, recovery, or return operations.

Steel Cable Reel

Spring Cable Reels

Spring cable reels are used on a variety of moving machinery to automatically reel in cables. Most hoisting and material handling devices, such as portal cranes, grabs, magnets, lift and working platforms, machines, excavators, mobile cranes, transfer vehicles, transport systems, and skimmers in purifying plants, fall into this category. These devices are usually track-based and run in a straight line. These applications for the transmission of electric power and control signals via reeling might be horizontal or vertical in orientation.

Spring Cable Reel

The motor springs have a long potential length and can produce a large number of revolutions, making them ideal for retrieving and returning applications. To retract cords, cables, and hoses, the motor springs can be directly linked to a reel. The spirator spring can use long deflections, which can be used in reels like a 100-foot cable reel to reduce total package weight and space. Single or double negator constant force springs are mounted on one or two storage drums and an output drum with an inbuilt cable reel respectively, in negator spring motor assemblies. A metal base plate supports the entire structure. Other materials, such as Inconel, Elgiloy, or high-carbon steel, can be used for bespoke applications.

Spirator prestressed power springs are made by reverse winding a negator spring on an arbor and then encasing it in a retaining ring or case. If a linear motion is required, a pulley and cable attachment can be used to obtain rotational energy from the case or arbor. When deflection and torque are equal, the spirator spring takes up 20% less space than a regular power spring and produces a flatter torque gradient. Power springs can be utilized for winding, counterbalancing, and retrieving in a variety of applications. Prestressed power springs are small and light, and they can provide more than twice the number of rotations as traditional power springs. In comparison to standard power springs, higher pre-stressing allows for the use of thinner material and consequently a smaller package size.

Motor-Driven Cable Reels

Mobile equipment, such as gantry cranes and indoor cranes, various loading devices, large-scale open-cast mining equipment, and longitudinal scraper bridges in purifying plants and traveling platforms, facilitate the transfer of energy and data. Transmission maintenance needs a system for storing and releasing cables that is always available and follows the movement of the equipment, preferably in a synchronized manner. At the same time, the equipment's application determines the basic pattern of movement - distance, direction, acceleration, speed, and mass.

Motorized Cable Reel

Cable reels with motor drive are a solution that fits these requirements. The reel body, drive, and slip ring assembly make up a motor-driven cable reel. Motorized hose reels, motor driven hose reels, motor driven cable reels, air hose reels, electric hose reels, and motorized hose reels are some of the alternative names for motor-driven cable reels.

Fixed Reels

This type of reel is distinguished from take-apart reels by the fact that it is permanently assembled. These reels are used to wound and unwind steel wire ropes and power cables and are found in lifting and hauling devices such as cranes, elevators, and ropeways.

Fixed Cable Reel

Hose Reels

Hose reels are used to wind, unwind, and store hose lengths used to transfer gasses and liquids in industrial settings. Hose reels come in a variety of materials, including steel, stainless steel, plastic, and wood. The majority of goods contain ports to keep fluid flowing during rewinding. Hose reels come in a variety of shapes and sizes.

Collapsible gadgets can be dismantled for storage or transportation. Portable hose reels, which usually have a handle, are designed to be moved by hand. Live connection reels have specific gear that keeps the material flowing while the hose is still attached to the reel. Storage reels are used to store continuous objects like cable, hose, paper, or rope for extended periods of time. A reel, hose, and integral hardware such as a nozzle make up a complete hose and reel assembly.

Hose reels can be rewound in a variety of ways. A hand crank is required for manual equipment. There are also products that use an electric motor, hydraulic motor, pneumatic motor, or internal spring. Shaft speed, terminal voltage, continuous current, continuous torque, and continuous output power are all used to describe electric motors. Operating torque, operating pressure, operating speed, operating temperature, power, maximum fluid flow, maximum fluid viscosity, and displacement per revolution are all used to rate hydraulic motors. Torque, maximum air pressure, air consumption, rated free speed, and operating noise level are all used to describe air motors.

Hose reels are useful for winding, unwinding, and storing a variety of industrial hoses. Reinforced hose comes in a variety of types, including textile braid, wire braid, wire helix, and other multi-ply or multi-layer arrangements, and is suited for heavy-duty applications. Industrial hose that has been coiled is flexible, elastic, and relatively easy to store. Corrugations, pleats, or spiral convolutions are used in corrugated hoses to promote flexibility, compression, and elongation capacity. Articulated industrial hose is made up of rigid hose sections with movable "joints" that can swivel, position, or articulate. Multiple hoses are created or glued together in a flat, ribbon, or bundled arrangement in a multi-element hose. Hose reels for pneumatic hoses and hydraulic hoses are also available.

Hose Cable Reel

Retractable Cable Reels

A retractable mechanism is included in certain cable reels. The wires on these reels typically transmit mains electricity, although air hoses employ a similar method. Retractable cable reels are very handy in situations where electricity or air is required in a variety of locations. A constant force spring provides torsion for the spool in all retractable hose reels, and a ratcheting mechanism prevents the cable from retracting while in operation.

Retractable Cable Reel

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Chapter 3: Applications and Benefits of Cable Reels

This chapter will discuss the applications and benefits of cable reels.

Applications of Cable Reels

  • Cable reels are used for on-site cable installation. The cable drum is used to secure and remove various sorts of cables from various locations. This type of equipment is a useful tool for cable installation and maintenance.
  • Mounted on shafts: shaft-mounted reels have a very easy-to-adjust cable tension, making them one of our most popular and adaptable cable retractors.
  • Cable reels are applied in vehicles, mostly off-road trucks. They are used to reel out the vehicle when it is stuck in mud for example.
  • Fiber optic cables are commonly packaged in steel reels made specifically for transporting and storing fiber optic wires. Light pulses created by tiny lasers or light-emitting diodes transport communication signals across fiber optic links (LEDs). The cable is made up of one or more glass strands that are each only a few millimeters thicker than human hair. The core is the part of each strand that offers a path for the light to go. A layer of glass called a coating surrounds the core and reflects light inward to reduce signal loss and allow light to pass through bends in the wire.

Cable reels are used to reel in and out the following materials:

  • Wires
  • Cables
  • Monofilaments
  • Fibers
  • Threads
  • Yarns
  • Ropes
  • Hoses
  • Flexible Tubes
  • Bands
  • Strips
  • Tapes
  • Films

Advantages of Cable Reels

The advantages of cable reels include:

  • Cable reel rollers, unlike reel jack stands, are a single, stationary piece of equipment. The reel rotates thanks to a low base with steel rollers smoothly. Workers may swiftly disburse cable after installing the reel in place without worrying about serious safety hazards caused by poor setup.
    Cable Reel Rollers

  • Cable reel rollers can improve operational efficiency over time because they're faster to put up and utilize than jack stands. While cable reel jack stands must be absolutely aligned to one another, reel rollers are one piece of equipment; once the roller has been properly positioned, employees can begin payout.
  • Reel rollers are often sturdier and longer lasting than jack stands, despite their higher initial cost. They're less likely to be misconfigured, which is important when dealing with large reels. Tie-down kits can also be used to secure them for increased dependability (more on tie-down kits in a moment).

Disadvantages of Cable Reels

They may not leave enough area for proper installation. When compared to trench rollers, the installation of a cable roller is rather simple. All you have to do now is locate the suitable location at the building's edge, lay down the cable, and feed the rollers into the proper position. If you can't find a good location, you may have to dig deep into the ground to put the rollers in place. If you can't manage the cable around corner bends and curves, you may need to invest in a cable roller with specific curved ends.

Handling of Cable Drums

  • Always keep an eye on the drum's condition. To reduce cable exposure to high temperatures, wooden drum battens, for example, should be left intact. To safeguard the cable, double-check that the drum is completely closed. To avoid harm, it is necessary to conduct regular assessments. Damaged reels should be replaced with undamaged reels for unwinding cable.
  • The drums should be kept upright at all times.
  • While handling the reels, small but crucial tasks like tightening the nuts, removing the fixing before stringing, and placing them on the level grounds should always be performed.
  • There are various sorts of cables. Temperatures should be maintained consistently depending on the type of cable for optimum effects and to keep it in good condition.
  • Reels should not be dropped.
  • Only unreel the wire by rolling the reels in the opposite direction (usually clockwise).
  • Keep the reels dry and indoors on a hard floor.
  • Tie reels in place with railroad ties to store them for a long period.

Maintenance Procedure of Cable Reels

  • Switch off the power source on the reel if it has electrical cables and clean the piece of equipment
  • Check the cable geometry (weaving, snaking) on a regular basis. If required, replace the cord.
  • Abrasion or puncture of the cable's outer sheath shouldn't be sticky. If required, clean
  • Check the contact surface of the rings (clean with a very dry cloth if necessary);
  • Dust from the insulating spacers and between the rings should be removed
  • Clean the rings with a light jet of dry air and check the connections
  • Inspect the tightness of the rings' bolts and threaded rods;
  • Inspect the quality and cleanliness of the brushes;
  • Inspect the wear of the brushes: replace if X 20 mm.

Conclusion

Cable reels hold conductive cable or lifting cable and are used for storage, unwinding, and winding. Contacts on electric cable reels keep the power on while winding. Reels are machines that wrap long, continuous goods like cable, wires, paper, and other materials for transport or storage. Simple storage systems such as reels are available, while more advanced versions are self-winding. They can also be ordered with live connections, allowing you to utilize a hose or electrical wire while it's still on the reel. The choice of a cable reel has to be cognizant of the different types, applications, and benefits of each one.

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Table of Contents

Principle of Cable Reels

Types of Cable Reels

Applications and Benefits of Cable Reels

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