KPJ Cable Reel Track Flat Car for Industrial Transport
Cable Reel Electric Flat Car
Model: KPJ series; Load capacity: 6-160 tons; Power supply: Cable reel; Travel speed: 20-30 m/min.
The KPJ series cable reel rail flat car is a proven product from Kelude Heavy Industry. It uses a hysteresis-coupled cable reel to automatically pay out and retrieve the power cable, with a travel distance of up to 200 meters, making it an ideal choice for medium-to-long-distance cross-bay transport. The cable reel is equipped with a torque motor to maintain constant tension on the cable at all times, preventing dragging wear or tangling.
The KPJ series is particularly suited for complex track layouts involving curves, switches, and other demanding conditions. The cable is paid out and retrieved with the car, eliminating the need for trench construction and simplifying installation and maintenance. These cars are widely used for heavy material transfer in steel mills, foundries, mines, ports, and other industries.
Product Introduction
The KPJ series cable reel powered flat car features a cable reel mounted on the car body. The reel is of the hysteresis-coupled type, ensuring even cable tension and preventing damage. The reel supplies 380V power to the YZ series motors designed for crane and metallurgical duty, which drive the car. As the car moves, the reel automatically winds or unwinds the cable. Due to the limited cable length on the reel, the maximum travel distance is generally less than 200 meters. Compared to the KPT cable-trolley system, the KPJ cable reel solution offers more controlled cable handling and less wear, making it better suited for longer travel distances (50-200 meters).
Product Images
Product Features
- Hysteresis-coupled reel: The cable reel uses a hysteresis-coupled design that maintains constant tension during payout and retrieval, effectively preventing cable breakage or tangled buildup and extending cable service life.
- Travel distance up to 200 meters: Compared to the KPT cable-trolley system (≤100 meters), the KPJ cable reel solution doubles the travel distance, covering a wider range of applications.
- Adapts to complex track layouts: Since the cable is paid out and retrieved by the reel, the car can handle curves, switches, and other complex track configurations with greater flexibility.
- No trench construction required: The cable is laid on the ground surface or overhead, eliminating the need for trench excavation, reducing installation costs and shortening project timelines.
- High load capacity: Standard capacities range from 6 to 160 tons, with larger custom capacities available to meet heavy industrial requirements.
Working Principle
The working principle of the KPJ series cable reel electric flat car is as follows: Mains power (three-phase 380V) is routed from a fixed power supply box through a cable, with the other end connected to the cable reel mounted on the car. The reel houses a hysteresis coupler and a torque motor. When the car moves forward, the cable is pulled off the reel, and the torque motor generates counter-torque to keep the cable taut. When the car moves in reverse, the torque motor actively rotates to neatly wind the cable back onto the reel.
The cable is routed through the collector slip ring inside the reel into the car's control box, supplying power to the YZ series crane and metallurgical duty motors. The key advantage of the hysteresis coupler is that the take-up torque automatically adjusts based on the length of cable paid out — the longer the cable payout, the higher the take-up torque — ensuring constant tension throughout and preventing the cable end from being overstressed and breaking.
Typical Applications
The KPJ cable reel rail flat car is designed for demanding crane and metallurgical duty environments. Its simple, robust construction, economical price, and easy track installation make it particularly well suited for the following scenarios: billet transfer between the continuous casting bay and rolling mill bay in steel plants (distances of 50-150 meters), cross-bay transport of molds and castings in foundries, large workpiece transfer between bays in heavy machinery workshops, material handling in mining stockyards and ports, and complex track layouts involving curves or switches.
Structural Composition
The KPJ series electric flat car consists of the following core structural components:
Frame: Fabricated from Q235B (≈S235JR) steel plate by welding, annealed to relieve internal stress. The main girder uses a box-section design, with load-bearing capacity optimized through FEA.
Cable reel assembly: The hysteresis-coupled cable reel is the core component, incorporating a torque motor and collector slip ring. Take-up torque automatically adjusts with the length of cable paid out, ensuring constant tension throughout operation. The cable is YCW-type heavy-duty rubber-sheathed cable, resistant to oil and abrasion.
Drive system: Powered by YZ series three-phase asynchronous motors (380V/50Hz) designed for crane and metallurgical duty, rated at 2.2kW-7.5kW × 2. The gearbox uses either worm gear or hardened tooth flank gear transmission.
Wheel assembly: Cast steel wheels with medium-frequency induction hardened tread surfaces (HRC45-50). Bearings are spherical roller bearings that automatically compensate for installation misalignment.
Electrical control system: The control box houses a circuit breaker, contactor, and thermal overload relay, providing overload and short-circuit protection. Standard configuration includes a pendant control, with wireless remote control available as an option.
Technical Parameters
| Parameter | KPJ 6t | KPJ 10t | KPJ 16t | KPJ 25t | KPJ 40t | KPJ 63t | KPJ 100t | KPJ 160t |
|---|---|---|---|---|---|---|---|---|
| Rated Load Capacity(t) | 6 | 10 | 16 | 25 | 40 | 63 | 100 | 160 |
| Table Dimensions LengthL(mm) | 3600 | 3600 | 4000 | 4500 | 5000 | 5600 | 6300 | 8000 |
| Table Dimensions WidthB(mm) | 2000 | 2000 | 2200 | 2200 | 2500 | 2500 | 2800 | 2800 |
| HeightH(mm) | 550 | 550 | 580 | 650 | 700 | 850 | 900 | 1150 |
| Travel Speed (m/min) | 30 | 30 | 30 | 30 | 25 | 25 | 20 | 20 |
| Bottom Clearance (mm) | 50 | 50 | 50 | 60 | 60 | 60 | 60 | 60 |
| Wheel Diameter (mm) | 400 | 400 | 400 | 500 | 500 | 600 | 600 | 600 |
| Gauge (Inside Rail Distance) C(mm) | 1435(Customizable 762-2000mm) | |||||||
| WheelbaseA(mm) | 2000 | 2000 | 2200 | 2500 | 2800 | 3200 | 3600 | 4500 |
| motor power (Kw) | 2.2 | 2.2 | 3.7 | 3.7 | 5.5 | 7.5 | 7.5 | 7.5×2 |
| Cable Specification | AC380V 3×2.5+1×1.5 | AC380V 3×6+1×4 | ||||||
| Reference Weight(t) | 2.2 | 2.5 | 3.2 | 4.3 | 5.7 | 8.3 | 10.2 | 22.5 |
| Recommended Crane Rail | P24 | P38 | P43 | P50 | ||||
| Number of Wheels /Wheel load | 4/2.2t | 4/3.3t | 4/5t | 4/7.5t | 4/11.5t | 4/18t | 4/27.5t | 8/22.8t |
Why Choose Kelude Heavy Industry
- 17 Years of Industry Experience: Kelude Heavy Industry specializes in the R&D and manufacturing of electric flat cars. Our KPJ series has been widely deployed in steel mills, foundries, and port projects both domestically and internationally.
- In-House Core Components: The hysteresis-coupled cable reel is independently designed and manufactured by Kelude Heavy Industry, delivering precise tension control and extended service life.
- Custom Engineering Capabilities: We tailor table dimensions, rail gauge, load capacity, and automation interfaces (PLC / remote control / unmanned operation) to match your specific operating conditions.
- Comprehensive After-Sales Service: A nationwide 24-hour response hotline, backed by on-site installation guidance, operator training, and scheduled inspections.
Service & Support
Henan Kelude Heavy Industry Co., Ltd. provides full life-cycle support for the KPJ series cable reel electric flat car: pre-sales solution design (recommending the right load capacity and reeling cable length based on your application), on-site installation & commissioning (our technicians supervise installation and trial runs), and post-warranty service (12-month warranty on the complete machine, 24-month warranty on motors and gearboxes). Spare parts are available on a long-term basis, and annual maintenance agreements can be arranged.
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FAQ
FAQ
Q: What is the maximum travel distance for the KPJ series cable reel flat car?A: The standard configuration supports a maximum travel distance of approximately 200 meters. Cable length depends on drum capacity and cable diameter — models from 6-40t come standard with 50m of cable, while 63-160t models include 80m. Longer distances are available with a custom enlarged drum.
Q: What's the difference between the KPJ cable reel flat car and the KPT cable pull flat car?
A: The KPJ uses a cable reel that automatically pays out and retrieves the cable, supporting travel distances up to 200 meters with minimal cable wear. The KPT uses a cable pulley block to drag the cable — simpler in construction but limited to shorter distances (≤100m). The KPJ is better suited for medium-to-long distances and complex routes with curves or switches, while the KPT is ideal for short, straight tracks.
Q: Does the hysteresis coupler on the cable reel require maintenance?
A: The hysteresis coupler is maintenance-free by design with no internal wearing parts. We recommend inspecting the carbon brush wear on the slip ring every 6 months and replacing as needed. The drum bearing should be greased once a year.
Q: Can the KPJ series electric flat car support remote control and automated operation?
A: Yes. It can be equipped with wireless remote control (effective range 100-200m), or integrated with a PLC and frequency inverter for multi-speed control, automatic positioning, and synchronized operation with overhead cranes or AGVs. The control system complies with JB/T 6127-2010 and GB 5226.1-2019 standards.
Q: Is the KPJ cable reel electric flat car suitable for outdoor use?
A: Yes. The KPJ series cable reel and electrical control cabinet feature IP54 protection, making them suitable for outdoor rain and snow conditions. The cable is a weather-resistant YCW rubber-sheathed type. For prolonged outdoor exposure, we recommend adding a rain cover for the drum.
