The HV multi-core cable is used, for example, as a connecting cable to the cabin heater, the e-compressor or the HV heat pump in electric and hybrid vehicles. The double EMC-shielded high-voltage cables with bare copper stranding and orange-colored TPE-U sheathing have a low-temperature resistance down to -50°C according to DIN EN 60811-506 and withstand temperatures of up to +125°C for a operating time of up to 2,000 hours. The extremely tensile, abrasion and shear resistant outer sheath allows tight bending radii and, in many cases, eliminates the need for installation with additional protective tubing. Other quality and safety features include flame-retardant and self-extinguishing material properties in accordance with IEC 60332-1-2 as well as standardized high resistance to mud, UV, ozone, and salt water. All materials are free of harmful substances and meet RoHS criteria. In addition to the standard designs, SAB Bröckskes also offers intermediate cross-sections of e.g. 8 mm2 as well as sheaths in other color variants on request.

Application Areas

Single Pair Ethernet cables can be used for different applications within diverse industries. The intended application is the key factor in the development of SPE cables.
For example, Single Pair Ethernet cables are suitable for fixed installation, mobile applications, and even highly flexible applications. For many industrial applications, high temperature-resistant and rugged SPE cables for indoor and outdoor installation are also required.

SAB’s focus is on two Single Pair Ethernet cables, which have been specially developed for the increasing data transmission rates in automation. In addition to the CATLine C-Track, a drag chain-compatible Single Pair Ethernet cable, SAB Bröckskes has also developed a robot-compatible SPE cable with UL recognition, the CATLine SPE Robot.

The drag chain- or robot-compatible SPE cables ensure safe and reliable data transmission over a bandwidth of 1-600 MHz. These cables are also PWIS non-critical, oil resistant, UL recognized, and RoHS compliant.

H4: SPE Network

As an early member of the SPE network, SAB Bröckskes’ ambition is to help establish SPE technology on the international market and drive new fields of application in the different industries. To this end, the cable specialist from Viersen has developed a complete product range for diverse applications:

CATLine SPE C-Track      Single Pair Ethernet cable, drag chain compatible
CATLine SPE Robot         Single Pair Ethernet cable, robot compatible
CATLine SPE HT              Single-Pair Ethernet cable, high temperature resistant
CATLine SPE Rugged      Single Pair Ethernet cable for rugged indoor & outdoor use
CATLine SPE Rail            Single Pair Ethernet cable for railway applications

Design and Manufacture of SPE Cables

Due to the high mechanical and transmission requirements of Single Pair Ethernet cables, the demands on design and production are also significantly higher compared to multi-pair stranded Ethernet cables. The manufacturing specifications must be complied with to the letter.

All Single Pair Ethernet Cables are designed as single pair cables (2 x AWG 26/7) and can also be designed as hybrid cables depending on the application. SAB expects a lot of application-related special solutions, e.g. with power supply for motors and sensors. SAB considers itself well positioned in this area and would like to offer custom solutions.

Design requirements differ depending on the application. For drag chain applications, a permanently flexible design with a specially adapted stranding technique was chosen for the CATLine SPE C-Track cable. For robot applications, the design was adapted to guarantee flexible use for a torsional application of +/- 180°.

Advantages over Traditional Ethernet Cables

Compared to a traditional 4-pair Ethernet cable, SPE cables save up to 30% on space and are up to 35% lighter. Considering the amount of cable that would be laid in km, the resulting cost savings are considerable. Over the life cycle of a railroad, for instance, you would be looking at savings somewhere within the 6-digit euro range.

Standards & Transmission Quality

A T1 SPE C-Track cable must meet the electrical and transmission requirements of draft standard CD IEC 61156-12 Ed. 1.0. Connectors are available from Harting, for example with which SAB Bröckskes works closely. Used in combination, full compliance with the standard is then assured.

Based on current information, SPE requires no more bandwidth than Cat.7A. SAB cables have already been successfully tested.

Special Solutions for Special Applications

SAB’s manufacturing capabilities extend not only to basic types and standard dimensions, but, in particular, to special cables designed according to each customer’s requirements. Production can also be carried out in small batch sizes, which are of interest for small and pilot series.

When designing USB 3.0 cable there are several challenges to consider for optimum performance and application compatibility. For example, for medical applications USB 3.0 cables should be lightweight, very flexible without memory effect to avoid kinking or craning. In addition, the cable should be autoclavable and flexible enough to be used with hand held devices. In order to ensure these characteristics, the choice of raw materials and manufacturing processes must be precisely coordinated. 

High-precision manufacturing processes for cable production

Asymmetries in cable can quickly lead to interferences due to differences in propagation time and signal radiation, while large process tolerances lead to mismatching and reflections. As a consequence, this can lead to transmission losses, distortion of the signal, runtime and data errors and ultimately to reduced image quality.

"The precision of the manufacturing processes and the selection of impedance-relevant materials have a considerable influence on the transmission characteristics", says Marc Gerlatzek, product manager for the medical technology division at SAB Bröckskes GmbH & Co KG. "Through targeted signal integrity engineering and comparison with our documented empirical values from a large number of measurements, we ensure homogeneous transmission values over the entire cable length.

Length-dependent factors such as "voltage drop" or attenuation are limiting factors. Cable cross sections for increased power transmission are just as much a part of the requirement profile as are tolerated outer diameters.

Customer-specific productions possible from 100m

In order to create or customize customer-specific specifications the cable specialist from Viersen rely on close customer contact. Once custom cable solutions are agreed upon cable manufacturers should guarantee exclusive manufacturing to dedicated production lines otherwise knowns as serial production to ensure from prototyping to mass production the manufactured process is controlled with no variances from separate production batches. Custom Cables with production minimums as low as 100 meters can be tested under real time conditions which enhances the experience between  customers and SAB specialists therefore addressing improvements and continuous success.

The halogen-free cable with highest flame protection and non-toxic characteristics is able to withstand weather conditions in outdoor use and shows at the same time a good oil and fuel resistance. Furthermore, it is resistant against mechanical stress and as a consequence is appropriate for the use in cable chains of construction machines or for door control systems in public transport.

Due to this extraordinary characteristics the cable can also be used in the bogie, as jumper cable or as sensor cable at the wheel set. SAB Bröckskes offers this cable as control cable with a nominal voltage of  300/500 V, as screened version, as paired data cable or designed for  a nominal voltage of 0,6/1 kV. Moreover, it is certified according to highest European fire  protection standards and has been tested by independent authorities.

The cables are tested acc. to the highest Hazard Level – HL 1 to 3 – for indoor and outdoor application acc. to EN 45545.

Outstanding features of the SAB RailLine 560:

• weather resistant
•  continuously flexible
• good ozone and UV resistance
• good oil and fuel resistance
• fulfils fire protection requirements R15 (EL1A) and R16 (EL1B)
  acc. to EN 45545-2 for hazard levels HL1-3

Today it is not quite clear how industry 4.0 in fully automated production will look like. Nevertheless, it is sure that a reliable transmission of increasing data volumes due to the steadily growing linking and communication of machine parts even under the most difficult conditions have to be ensured. As a consequence cables especially for machine construction, robotics or railway techniques are subject to extreme torsional stress and very high temperatures. These cables get in contact with different chemicals, oils or detergents. Also the subject of longevity with respect to industry 4.0 in industrial sectors are of basic importance.

70 years after its foundation, SAB Bröckskes presents itself highly innovative as answer to the mega trends of digitisation and industry 4.0 . The company presents a range of new industrial Ethernet cables 6, 6A, 7 and 7A that are not only extremely robust but also ensure a quick and efficient data transmission.

SAB is not only a cable manufacturer but also offers support in automation technique for example in the range of new communication systems for drive technology. Herewith, the individual requirements of the customer and the long-term experience of SAB as manufacturer of highly flexible cables are combined in new products . The quick and flexible production of sample lengths is no problem at all.

The cable manufacturer focus on two Industrial Gigabit Ethernet cables that have been especially developed for the increasing data transfer in automation technique. Besides the world innovation CATLine CAT 7A RT, a CAT 7 A cable for robot application, SAB Bröckskes is also going to present a cable chain cable with UL/ CSA approval – the CATLine CAT 7 A S. 

Industrial Ethernet Cables and Wires Category 6A and 7A:

CATLine CAT 7 A RT – for robot application Gigabit Ethernet cable with UL/ CSA 
The cable CATLine CT 7 A RT for robot application is suitable for rough industrial conditions in automation technique for example at high temperatures, pollution by oil and aggressive chemicals.

 CATLine CAT 7A S – for cable chain application Gigabit Ethernet cable with UL/ CSA 
The cable chain cable CATLine CAT 7A S is suitable for rough industrial conditions in cable chains for example at high temperatures, pollution by oil and aggressive chemicals.

 CATLine CAT 6A HT – temperature resistant 
The temperature resistant cable CATLine CAT 6A HT is suitable for rough industrial conditions at temperatures up to fixed: -90°C/+ 180°C flexible: -55°C/ + 180°C.

CATLine CAT 7A DR reeling CAT 7A Gigabit Ethernet cable
Our reeling CATLine CAT 7A cables have been developed for different applications whenever a considerable data volume must be transferred safely. They are for example used in stage technique of theaters, signal transmission and mobile trash rake cleaning or in high rack storage technique.

CATLine CAT 7A R – Rail CAT 7A
CATLine CAT 7A R acc. to DIN EN 45545-2, is especially appropriate for rail applications. The cable fulfills the requirements on no flame propagation of DIN EN 60332-3-25 + DIN EN 50305 section 9.1.1 + 9.1.2 and is flame retardant and self-extinguishing acc. to DIN EN 60332-1-2

Special solutions for special applications

The production possibilities of SAB range from basic types and standard dimensions to special cables according to the individual requirements of our customers.

New productions are already possible for small quantities – especially interesting for small and pilot productions.