Powered reeling drums like the ones you’ll find here at Metreel are widely used in industrial environments. They are used to wind and unwind cables automatically on equipment such as cranes, hoists, stackers, reclaimers, mobile machinery and port equipment.
As with all types of industrial equipment, ensuring the right parameters are met is key to the safe and efficient usage of the equipment. In terms of reeling drums, those parameters are tension and layering. That’s because only if the right conditions are met can the cables wind and unwind neatly, safely and with minimal wear.
If you use a powered reeling drum and it has poor tension or layering, you may notice one of a number of common problems. This includes cable crushing between layers, cable bird-nesting or bunching, abrasion due to rubbing or crossovers, electrical faults due to conductor fatigue, drum damage, flange damage or misalignment causing uneven spooling.
Any of these issues can be dangerous, not to mention costly. So, in today’s post, we’re here to guide you on cable tension and layering in powered reeling drums to help you keep your equipment in safe working order.
What Is Cable Tension?
Cable tension describes the controlled pulling force applied to the cable as it is wound onto the drum.
That tension is needed because a lack of tension can result in the cable becoming slack. Additionally, the layers would become uneven and the cable may cross over itself unpredictably.
However, with the correct tension, the cable will wrap firmly and evenly. Each layer smoothly follows the previous one, enabling the cable to stay guided on the correct pitch.
In terms of how tension is controlled, powered reeling drums often have mechanical springs, magnetic or torque motors, friction clutches and electronic tension control systems. These all aid in keeping the tension consistent, even across different operating speeds.
What Is Cable Layering?
Cable layering describes how the cable builds up on the drum in organised layers, one over the other.
Different layering types exist to cater to varying operational requirements. They include:
Random lay
- Cable winds without a strict pattern
- Best for short cable lengths or flexible cables
- Low tension required
Level lay (parallel lay)
- Cable winds in neat, parallel rows
- Requires strict tension control
- Produces minimal cable wear
Helical lay
- Cable winds at a fixed helix angle
- More common in heavy industrial PRDs – AKA what we’re discussing in this post
Look out for signs of poor layering, which can be the result of low tension, the wrong drum design, damaged cable guides or incorrect alignment.
Proper layering matters because it helps prevent cable damage, reduces wear on sheaves and drums, ensures smooth payout and retraction and prevents sudden tension spikes. Each of these factors works to maximise the life of the cable and its performance.
How Tension And Layering Interact
When it comes to powered reeling drums, the key thing to know about tension and layering is that they are inseparable.
If there’s low tension, then there’s also poor layering. In which case, the cable may become loose, overlap irregularly, pinch or flatten. Drum damage may also occur.
Excessive tension can also result in cable damage. That’s because when the tension is too high, it can put excessive strain on conductor cores, lead to higher temperature buildups and ultimately, premature cable failure.
In short, balanced and consistent tension is essential for correct layer formation and long cable life.
Best Practices To Ensure Proper Cable Tension And Layering
- Use a correctly sized drum for the cable diameter
- Keep tension within the manufacturer’s recommended range
- Maintain cable guides and alignment systems
- Ensure constant tension during acceleration or deceleration
- Inspect cables regularly for flattening or deformation
- Avoid sudden load changes on the drum
- Use high-quality reeling-grade cables
Shop Powered Reeling Drums At Metreel
Metreel specialises in powerfeed equipment, including powered reeling drums. So, if you’re looking to upgrade your existing setup or purchase a reeling drum for the first time, you’re in the right place.
Head over to our powerfeed product solutions to learn more.
Or, if you have a question about purchasing powered reeling drums, please get in touch.
You can also give us a call on 0115 932 7010.