Flugzeugheber-T Hybrid PUR Trailing Cable for Aircraft Assembly Robots
Flugzeugheber-T is a hybrid trailing cable for the mobile support and positioning robots used in aircraft assembly: 600/1000 V power cores, 300/500 V control cores and screened data pairs for the positioning laser, under a PUR sheath with an integrated support braid.
- Power cores600/1000 V
- Control cores300/500 V
- Data pairs0.34 mm², foil and braid screened
- ConductorBare copper, Class 6
- Flexing temperature-20 °C to +80 °C
- Bending radius15 × cable diameter
- Outer diameterApprox. 25.6 mm or 27.0 mm
- SheathPUR with support braid
Flugzeugheber-T is a hybrid trailing cable for the support and positioning robots that lift and hold aircraft sections during assembly. One cable carries the 600/1000 V supply for the drives, the 300/500 V control circuits and screened twisted data pairs for the positioning laser system, so a robot that moves across the hangar floor trails a single cable instead of three.
The cable is built in two versions: 70736 with a grey sheath and 2 × 2 × 0.34 mm² data pairs, and 77548 with an orange sheath, 18 control cores and 4 × 2 × 0.34 mm² data pairs. Both use extra-fine Class 6 bare copper conductors and a PUR outer sheath with an integrated support braid that takes the pulling load when the cable is dragged.
Browse the Port Crane Cable category for related cables or download the Flugzeugheber-T datasheet (PDF).
Application & Features
Selection overview
In aircraft assembly, fuselage and wing sections are lifted, held and aligned by mobile support robots and jacking systems. Each unit needs drive power, control signals and a clean data link for the laser that measures its position, and it moves across the floor while the cable trails behind it. A hybrid cable keeps that moving connection to one jacket, with the data pairs screened against interference from the power cores and a support braid that protects the cores when the cable is pulled.
The same build suits other mobile lifting and material-handling equipment that trails a combined power, control and data cable. For crane festoons and reeling drums, see our port crane cables, such as the Trommelflex PUR festoon cable.
- Power, control and dataDrive supply, control cores and screened data pairs in one trailing cable.
- Screened data pairsFoil wrap plus tinned copper braid, approx. 85% coverage, for the positioning laser link.
- Support braidIntegrated braid under the PUR sheath takes the pulling load when the cable is dragged.
- PUR sheathResists abrasion, oil, hydrolysis, microbes and UV; flexible down to -20 °C.
Specifications
Technical data
Nominal values for Flugzeugheber-T versions; dimensions and weights are approximate and subject to manufacturing tolerances. The final construction is confirmed on the TEBAOFLEX datasheet issued with your quotation.
Electrical, thermal and material data
| Parameter | Value |
|---|---|
| Conductor | Bare copper, extra-fine high-flexibility conductors, Class 6 |
| Conductor standard | DIN VDE 0295 Class 6; BS 6360 Class 6; IEC 60228 Class 6 |
| Power/control core insulation | Cold-flexible PVC or TPE-E, black numbered cores |
| Power-core voltage | 600/1000 V |
| Control-core voltage | 300/500 V |
| AC test voltage, 50 Hz | Power cores 4000 V; control cores 1500 V |
| Data pairs | 0.34 mm² polyethylene-insulated twisted pairs, foil wrapped, tinned copper braid screen |
| Data-pair screen coverage | Approx. 85% |
| Flexing temperature | -20 °C to +80 °C |
| Minimum bending radius | 15 × cable diameter for flexible installation |
| Outer sheath | PUR with integrated support braid; grey (70736) or orange (77548) |
| Sheath performance | UV resistant; resistant to oil, hydrolysis and microbial attack |
Flugzeugheber-T versions
| Version | Power/control structure | Data pairs | Outer diameter approx. mm | Weight approx. kg/km | Rated voltage | Bend radius |
|---|---|---|---|---|---|---|
| 70736 | 5 x 4 mm² + 5 x 3G 0.75 mm² | 2 x 2 x 0.34 mm², screened | 25.6 | 600 | 600/1000 V power; 300/500 V control | 15 x D |
| 77548 | 5 x 2.5 mm² + 18G 1.0 mm² | 4 x 2 x 0.34 mm², screened | 27.0 | 750 | 600/1000 V power; 300/500 V control | 15 x D |
Selection note: Before ordering, ask our engineers to confirm the core layout against your robot's power, control and data connections, the pulling load and travel length, and the sheath color you need.
Standards & References
Applicable standards and compliance
- ConductorClass 6 extra-fine bare copper to DIN VDE 0295, BS 6360 and IEC 60228.
- RatingsPower cores 600/1000 V and control cores 300/500 V, tested at 4000 V and 1500 V AC, 50 Hz.
- Data screeningFoil wrap plus tinned copper braid, approx. 85% coverage, over the 0.34 mm² data pairs.
- ApprovalsMarkings and any customer approvals for your order are confirmed and quoted per order.
Construction
Material and build-up
Flugzeugheber-T combines three kinds of circuit under one PUR sheath: power cores, numbered control cores and a screened data element, with a support braid for trailing service.
- Conductors: Class 6 extra-fine bare copper for continuous flexing.
- Power and control cores: cold-flexible PVC or TPE-E insulation, black cores with numbers; power cores rated 600/1000 V, control cores 300/500 V.
- Data element: 0.34 mm² polyethylene-insulated twisted pairs, foil wrapped and screened with a tinned copper braid of approx. 85% coverage.
- Support braid: integrated under the outer sheath to carry the pulling load.
- Outer sheath: PUR, grey for 70736 and orange for 77548; resists abrasion, oil, hydrolysis, microbes and UV.
FAQ
Selection questions
What is a hybrid trailing cable?
It is one flexible cable that carries power, control and data to a moving machine and is dragged behind it. Flugzeugheber-T combines 600/1000 V power cores, 300/500 V control cores and screened 0.34 mm² data pairs under a PUR sheath with a support braid.
What is the difference between 70736 and 77548?
70736 has a grey sheath, 5 groups of 3G 0.75 mm² control cores and 2 × 2 × 0.34 mm² data pairs, with an outer diameter of approx. 25.6 mm. 77548 has an orange sheath, 5 × 2.5 mm² power cores, 18G 1.0 mm² control cores and 4 × 2 × 0.34 mm² data pairs, with approx. 27.0 mm diameter.
Why are the data pairs screened separately?
The positioning laser link must stay clean while the drive cores in the same cable carry load current. A foil wrap and a tinned copper braid of approx. 85% coverage around the pairs keep the data signal separate from the power cores.
Can the core layout be changed?
Yes. The power, control and data counts can be adapted to your robot. Send the connection list and our engineers will propose a construction.
What should I send for a quotation?
Send the version or your required core layout, travel length, pulling load, lowest working temperature, sheath color and quantity. Our engineers confirm the construction on the datasheet issued with your quotation.
Request this cable.
Send the version or core layout, travel length, pulling load, sheath color and quantity, and we will confirm the construction and quote.
Quality Assurance
Testing at every stage in our own workshop and laboratory, from incoming copper to the packed drum.
Raw Material Inspection
Every batch of copper rod, rubber compound and reinforcing material is checked before it reaches the line.
- Copper: conductor resistance, elongation and surface condition on incoming rod and drawn wire
- EPR, CPE, PUR and silicone compounds: hardness, tensile strength, elongation and ageing samples from each mix
- Suppliers and batch numbers are recorded so every drum can be traced back to its materials
Manufacturing Process Control
Stranding, insulation extrusion, core assembly and sheathing run under recorded process parameters.
- Class 5/6 stranding with lay length and tension monitored for trailing and reeling flexibility
- Continuous-vulcanisation extrusion with wall thickness and spark tests logged on every length
- Operators sign off each stage before the cable moves to the next machine
Electrical Testing
Finished lengths go through the routine tests required by the referenced VDE, ICEA, IEC or NEK standard.
- Conductor resistance and insulation resistance on every length
- Voltage withstand (3.5 kV and higher) and partial-discharge measurement in the shielded HV laboratory
- Screen and pilot-core continuity checks for mining and reeling constructions
Mechanical and Ageing Tests
Samples from production are tested for the duty a mining, crane or submersible cable will actually see.
- Tensile strength and elongation of insulation and sheath before and after ageing
- Hot-set, ozone, oil-immersion and low-temperature bending tests
- Constant-temperature water bath for insulation resistance of submersible constructions
Flame Test and Final Inspection
Before packing, the cable is checked against the order and the flame-performance requirement of its standard.
- Single-cable vertical flame test to IEC 60332-1-2 where specified
- Metre marking, printing, drum length and appearance inspection
- Test report and packing list issued with every shipment
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