ingiant technology | Industry new | April 25.2025
The internal structure of the cable reel is composed of power and transmission, winding, electrical connection, protection and auxiliary systems. Each part works together to ensure the safe retraction and transmission of the cable. The following takes a common electric cable reel as an example to introduce its internal structure:
1. Power and transmission system
a. Drive motor: Provides power for cable winding and release. Common types include AC motor, DC motor, torque motor, etc. For example, in the cable reel of large port cranes, high-power AC motors are mostly used to meet the needs of frequent and high-intensity operations; while the cable reels of some small equipment may use DC motors for precise control.
b. Reducer: Connects the drive motor and the reel shaft to ensure that the reel can smoothly drive the cable to be retracted and released by reducing the motor speed and increasing the output torque. It is composed of a gear set inside, and different gear ratios can be adapted to different working scenarios. For example, in situations where the cable needs to be retracted and released quickly, a reducer with a suitable transmission ratio will be selected.
c. Coupling: Used to connect the motor shaft with the reducer input shaft, the reducer output shaft with the reel shaft, and plays the role of transmitting torque, compensating for the relative displacement of the two shafts, and buffering vibration reduction. Common ones include elastic couplings and rigid couplings.
2. Winding system
a. Reel: It is the main part of the cable winding, usually made of metal material, with sufficient strength and rigidity to prevent deformation during winding. The diameter and width of the reel are designed according to the length, outer diameter and other parameters of the cable. For example, the diameter and width of the cable reel for long-distance power transmission are larger.
b. Wire arrangement device: Ensure that the cables are neatly arranged on the reel to avoid tangled wires and overlapping wires. There are two common methods: screw wire arrangement and fork wire arrangement. Screw wire arrangement drives the wire arrangement device to move axially through the rotation of the screw; fork wire arrangement relies on the swing of the fork to achieve cable arrangement.
3. Electrical connection system
a. Collector slip ring: It realizes the transmission of power and signals between the rotating reel and the fixed equipment. It is composed of conductive rings, brushes and other components. The conductive ring rotates synchronously with the reel, and the brush is connected to the external circuit and maintains sliding contact with the conductive ring to ensure stable transmission of current and signals. In the cable reel of complex control systems, the collector slip ring can also transmit many different types of signals.
b. Electrical control components: including controllers, contactors, relays, fuses, etc., which are used to control the start, stop, forward and reverse rotation of the motor and protect the circuit safety. The controller controls the motor speed and reel action according to the equipment operation requirements; the contactor and relay realize the on-off control of the circuit; the fuse cuts off the current when the circuit is overloaded or short-circuited to protect the safety of equipment and personnel.
4. Protection and auxiliary systems
Shell: protects the internal structure of the reel from external environmental influences, such as dust, water vapor, mechanical collision, etc. It is generally made of metal or high-strength plastic and has a certain protection level, such as IP54, IP65, etc. The higher the number, the stronger the protection performance.
Function of slip ring
The slip ring inside the cable reel is mainly composed of two parts: the rotor with signal input/output wires and the stator. When the cable reel rotates, the rotor rotates at any angle following the device, while the stator remains relatively still. This design allows the slip ring to transmit signals and currents from one location to another while the device rotates, thereby achieving continuous transmission of the cable and avoiding twisting and entanglement of the cable.
Ingiant high power and high current slip ring
a. High current conductive slip ring is designed to pass high power and high current, the maximum current can reach 1000A, with extremely low contact resistance contacts, low heat generation, ultra-high current housing is designed with aluminum alloy, fast heat dissipation, and a large number of heat dissipation holes. Each unit has temperature rise test and high current impact test before leaving the factory!
b. It can pass 30A, 60A, 100A and even customized products up to 1000A
c. Support 500W, 1000W, 2000W and higher power equipment.
d. Military technology gold plating treatment, extremely low contact resistance, low heat generation.
e. Each unit will be tested for temperature rise and high current impact before leaving the factory.
f. Shaft installation or flange installation is optional.
g. Outlet or terminal is optional.
h. Various types of high current slip rings, high power slip rings, small wind power slip rings, etc. can be customized.
The conductive slip ring is a key component of the cable reel, and its performance directly affects the operating stability and reliability of the cable reel. When using it, you need to pay more attention to the installation, operation, maintenance and other links to give full play to its role and ensure the normal operation of the equipment.
Installation link
Accurate alignment: When installing the conductive slip ring, be sure to ensure the concentricity of the rotor and the stator.
Stable installation: Use a suitable fixing method to firmly install the conductive slip ring on the cable reel.
Reasonable wiring: The wire connecting the conductive slip ring should be reasonably planned to avoid interference with the rotating parts of the reel.
Operation phase
Avoid overload: Strictly operate according to the rated current, voltage and speed of the conductive slip ring, and do not use it under overload.
Control speed: Different types of conductive slip rings have their maximum allowable speed limits.
Pay attention to the environment: The working environment of the conductive slip ring has a great impact on its performance.
Maintenance
Regular cleaning: Clean the conductive slip ring regularly to remove dust, oil and other impurities on the surface
Check wear: Check the wear of the brush and conductive ring regularly. When the brush wear exceeds 1/3 of the original thickness, it should be replaced in time to avoid affecting the contact effect and transmission performance.
Lubrication: Lubricate the parts that need lubrication regularly according to the instructions of the conductive slip ring.
FAQS
1. How to judge whether the concentricity of the conductive slip ring meets the standard during installation?
During installation, you can use tools such as dial indicators, place the meter head against the outer surface of the slip ring rotor, slowly rotate the rotor, and observe the changes in the dial indicator reading. Generally speaking, the concentricity error needs to be controlled within ±0.05mm. If the reading deviation exceeds this range, the slip ring position needs to be readjusted until it meets the standard.
2. What will happen if the tightening torque of the fixing bolts is too large or too small during installation?
If the tightening torque is too large, the slip ring housing may be deformed, the internal components may be unevenly stressed, and the normal contact between the brush and the conductive ring may be affected; if the tightening torque is too small, the slip ring is easy to loosen during operation, making the signal transmission unstable, and even causing damage to the slip ring. Be sure to tighten the bolts according to the torque specified in the product manual.
3. What fault phenomena will occur when the conductive slip ring is overloaded?
When overloaded, the slip ring will heat up significantly, the temperature will rise sharply, and sparks and smoke may be generated between the brush and the conductive ring. Long-term overload will also accelerate component wear, leading to interruption of signal transmission, unstable power transmission, and even burning of slip rings in severe cases.
4. How to choose a suitable cleaner to clean the conductive slip ring?
Use a dry, clean, non-cotton cloth to wipe the slip ring, and avoid using cleaners containing corrosive ingredients such as alcohol and acetone. If there is a lot of oil on the surface of the slip ring, use a special electronic equipment cleaner, which evaporates quickly and does not leave any harmful substances.
Post time: Apr-25-2025