FibreMax lightweight precision cables are produced by using an unique and one-of-a-kind production process. All cables are produced with endless winding technology which is a totally automated process of continuous winding of parallel strands of fibres around two end fittings until the right cable strength or required cable stretch has been reached.
1. Endless winding
After the required length has been programmed, the EWR (endless winding robot) computer calculates the amount of fibres and the amount of loops required for the specified cable. During the winding process the EWR maintains an equal tension in all fibres with an accuracy of 0,1%. This results in the highest break load, lowest stretch and lowest possible diameter. It also ensures that cables are produced with high repeatability; when producing multiple cables we can garantuee that all cables will have exactly the same specifications.
FibreMax designs EWT cables up to 300 mm dia. and > 4.000 mT break load.
When the desired amount of loops has been reached the cable is compressed by a strong and lightweight "wrap-around" tape to ensure minimal diameter and protection of the fibres. After this tape has been wrapped around the cable, another light, but strong, self-adhesive tape is automatically wrapped around the cable. These two layers of tape act as a particle filter layer to limit the amount of particles from protruding and destroying the fibres.
Compressing the fibres.
Cable end fitting before braiding.
3. Braiding (covers)
One or more covers are applied to the cable for protection against wear and abrasion. These covers are braided in-house from polyester, aramid, HMPE or other suitable material. The FibreMax standard cable protection consists of three heavy duty polyester braids. The inner braid is red to warn of excessive wear or damage of the outher braid, which are black or at least of a contrasting colour. When needed the cable can be provided with a special low drag surface to reduce vortex-induced vibration (VIV). Because of their very light weight FibreMax cables already have a higher natural frequency than steel wire ropes. A special coating can be applied to improve the properties of the protective braids. The colour of this coating can be adapted to customer's request. Other protection methods are available upon request. All cables are equipped with a RFID track-and-trace system which gives information on all production data of the cable. This will allow our service department to identify any cable in the event of a return for service or testing.
Braiding of covers.
Braiding of covers.
4. End terminations
The end terminations are directly included in the EWT cable manufacturing process and are fitted with a steel protective cover after the sealing/wrapping process. The steel cover protects against impact. The end terminations can be designed to the customer’s requirements to suit the application and existing connections.
FibreMax cables can be certified according to DNV, Lloyds and other key standards. If necessary the cables can be supplied with a certificate stating the ABL (Actual Breaking Load) or proofload specified by the customer.
End termination cable 700mT MBL
Cables ready after production