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Tsubaki Kabelschlepp
Cable and Hose Carrier Systems in Mobile Broadcasting
Live Broadcast without Time-Out
Cable and hose carrier systems manufactured by KABELSCHLEPP and installed, for example, in media trucks help ensure reliable transmissions. Such an outside broadcast or OB van, owned by the German media company Studio Berlin Adlershof and built by the Thomson subsidiary Grass Valley, is outfitted with 30 KABELSCHLEPP cable and hose carrier systems of series KC 0650 to make sure that every soccer goal as well as all other current events actually make it to your TV.
Studio Berlin owns an HDTV (High Definition Television) media truck equipped with up to 25 HD-cameras, a 4 layer-video mixer with 62 ports and an audio mixing console. This Studio Berlin vehicle named “OB Unit 6” features a 3-axle semi-trailer and a 2-axle power engine with a total weight of 40 tons as well as a length of 54 feet (16.5 meters) and a height of 13 feet (4 meters). The truck is 8.36 feet (2.55 meters) wide in retracted mode, compared to nearly 15 feet (4.5 meters) when its work compartments are extended.
This media truck is a fully equipped, mobile television studio. New electronic components are constantly added and affect the cable package. The higher broadcast frequency of the HDTV- signal has a critical impact on the cable wiring, e.g. the HDTV cables may not be crushed and have to comply with specific minimum bend radii requirements.
Extendable work compartments create additional space
The approximately 3.28 feet (1 meter) extendable side compartments have to be flexibly wired to the base unit together with data signal and power cables as well as coolant hoses. Grass Valley relies on cable and hose carrier systems manufactured by KABELSCHLEPP to safely protect its cables and hoses and has been working in similar projects with KABELSCHLEPP for several years already. In cooperation with the KABELSCHLEPP sales engineers, Grass Valley determined the cable carrier type, size and bend radii for its Studio-Berlin application and selected the hybrid carrier series KC 0650 with nylon side bands and aluminum frame stays.
Varitrak KC 0650 carriers with an inner cavity height of 1.50 inches (39 mm) are available as a hybrid design that features aluminum frame stay bars and glass-fiber reinforced nylon side bands. Carrier widths can be customized in 1 mm width increments. This feature was a major selling point for the Grass-Valley design engineering team. Due to their substantial cable package as well as space constraints in the cavity partitions, not a single millimeter could be wasted, which would have been the case with larger width increments. Solid nylon carriers always come in pre-determined increments, such as 0.31 inches or 0.62 inches (8 mm or 16 mm) spacing. The hybrid design solution literally utilized every single millimeter of the cavity partitioning.
Varitrak KC carriers are extremely durable due to their robust pin snap-together link design and encapsulated wear-resistant stroke system. The optimized carrier design evenly displaces push-pull forces thanks to its innovative “2 Disc Principle” link connections.
Cable carrier systems need to open and close quickly
One feature of the selected carriers in particular was extremely important to the customer: Due to the cables being harnessed with connectors of different sizes, it was impossible to in¬sert these cables into the carriers without opening the tracks. Thus, these approximately 6.56 feet (2 meters) long cable carrier systems are required to easily open and close for cable and hose installation. KABELSCHLEPP carrier system Varitrak series KC does exactly that. By simply twisting on or by twisting off the frame stays 90 degrees, cables and hoses can be very quickly and easily laid inside the carrier cavity and installed from either the inside radius or the outside radius.
Because of space constraints, the individual carriers are arranged in a nested operating mode with one carrier mounted inside the other. The inner carrier contains cables with a small and thus insignificant minimum bend radius, while hoses and cables with critical bend radii are in¬stalled in the outer carriers. The outer track with a bend radius of 6.89 inches (175 mm) carries, in addition to other cables, the sensitive Triax camera cables with a diameter of 0.55 inches (14 mm). The inner carrier has a bend radius of 4.53 inches (115 mm). A total of 30 cable carrier systems had to be mounted inside Studio Berlin’s media truck in an area measuring approxi¬mately 8.2 feet x 42.65 feet (2.5 x 13 meters): two pairs of carrier systems were used for audio, nine pairs for image production as well as image technology, and four pairs of cable carrier systems for slow motion pictures.
These cable diameters vary between 0.19 inches and 0.55 inches (4.7 mm and 14 mm). In addition, coolant hoses are installed in some of these carriers that, together with the required insulation, occupy the complete cavity height. To safely guide, protect and separate such a variety of different cables and hoses, dividers are used for vertical partitioning of the carrier’s cavity into individual compartments.
These carriers are required to comply with very high quality standards and must be designed for a very long service life. Furthermore, extreme care is required to safely guide and protect these cables in order to prevent failure. Aluminum frame stays are the perfect match showing how KABEL¬SCHLEPP, the reliable expert in cable and hose carrier systems, provides solutions for challenging applications.
Captions
KC_Detail.jpg: Grass Valley selected KABELSCHLEPP hybrid series KC 0650 cable carriers featuring glass-fiber reinforced nylon side bands and cable-friendly aluminum frame stays.
U-Wagen_CloseUp1.jpg: Due to space constraints, two cable carrier systems are arranged in nested operating mode rotated 90 °.
U-Wagen_CloseUp5.jpg: Fully harnessed cable and hose carrier systems: view of the installed cable and hose package. Cables and hoses of various sizes are separated by a divider system.
U-Wagen.jpg: 40 ton technology: HDTV-media truck “OB Unit 6” built by Grass Valley and equipped with up to 25 cameras, a 4 layer-video mixer with 62 ports and an audio mixing console.
Studio Berlin owns an HDTV (High Definition Television) media truck equipped with up to 25 HD-cameras, a 4 layer-video mixer with 62 ports and an audio mixing console. This Studio Berlin vehicle named “OB Unit 6” features a 3-axle semi-trailer and a 2-axle power engine with a total weight of 40 tons as well as a length of 54 feet (16.5 meters) and a height of 13 feet (4 meters). The truck is 8.36 feet (2.55 meters) wide in retracted mode, compared to nearly 15 feet (4.5 meters) when its work compartments are extended.
This media truck is a fully equipped, mobile television studio. New electronic components are constantly added and affect the cable package. The higher broadcast frequency of the HDTV- signal has a critical impact on the cable wiring, e.g. the HDTV cables may not be crushed and have to comply with specific minimum bend radii requirements.
Extendable work compartments create additional space
The approximately 3.28 feet (1 meter) extendable side compartments have to be flexibly wired to the base unit together with data signal and power cables as well as coolant hoses. Grass Valley relies on cable and hose carrier systems manufactured by KABELSCHLEPP to safely protect its cables and hoses and has been working in similar projects with KABELSCHLEPP for several years already. In cooperation with the KABELSCHLEPP sales engineers, Grass Valley determined the cable carrier type, size and bend radii for its Studio-Berlin application and selected the hybrid carrier series KC 0650 with nylon side bands and aluminum frame stays.
Varitrak KC 0650 carriers with an inner cavity height of 1.50 inches (39 mm) are available as a hybrid design that features aluminum frame stay bars and glass-fiber reinforced nylon side bands. Carrier widths can be customized in 1 mm width increments. This feature was a major selling point for the Grass-Valley design engineering team. Due to their substantial cable package as well as space constraints in the cavity partitions, not a single millimeter could be wasted, which would have been the case with larger width increments. Solid nylon carriers always come in pre-determined increments, such as 0.31 inches or 0.62 inches (8 mm or 16 mm) spacing. The hybrid design solution literally utilized every single millimeter of the cavity partitioning.
Varitrak KC carriers are extremely durable due to their robust pin snap-together link design and encapsulated wear-resistant stroke system. The optimized carrier design evenly displaces push-pull forces thanks to its innovative “2 Disc Principle” link connections.
Cable carrier systems need to open and close quickly
One feature of the selected carriers in particular was extremely important to the customer: Due to the cables being harnessed with connectors of different sizes, it was impossible to in¬sert these cables into the carriers without opening the tracks. Thus, these approximately 6.56 feet (2 meters) long cable carrier systems are required to easily open and close for cable and hose installation. KABELSCHLEPP carrier system Varitrak series KC does exactly that. By simply twisting on or by twisting off the frame stays 90 degrees, cables and hoses can be very quickly and easily laid inside the carrier cavity and installed from either the inside radius or the outside radius.
Because of space constraints, the individual carriers are arranged in a nested operating mode with one carrier mounted inside the other. The inner carrier contains cables with a small and thus insignificant minimum bend radius, while hoses and cables with critical bend radii are in¬stalled in the outer carriers. The outer track with a bend radius of 6.89 inches (175 mm) carries, in addition to other cables, the sensitive Triax camera cables with a diameter of 0.55 inches (14 mm). The inner carrier has a bend radius of 4.53 inches (115 mm). A total of 30 cable carrier systems had to be mounted inside Studio Berlin’s media truck in an area measuring approxi¬mately 8.2 feet x 42.65 feet (2.5 x 13 meters): two pairs of carrier systems were used for audio, nine pairs for image production as well as image technology, and four pairs of cable carrier systems for slow motion pictures.
These cable diameters vary between 0.19 inches and 0.55 inches (4.7 mm and 14 mm). In addition, coolant hoses are installed in some of these carriers that, together with the required insulation, occupy the complete cavity height. To safely guide, protect and separate such a variety of different cables and hoses, dividers are used for vertical partitioning of the carrier’s cavity into individual compartments.
These carriers are required to comply with very high quality standards and must be designed for a very long service life. Furthermore, extreme care is required to safely guide and protect these cables in order to prevent failure. Aluminum frame stays are the perfect match showing how KABEL¬SCHLEPP, the reliable expert in cable and hose carrier systems, provides solutions for challenging applications.
Captions
KC_Detail.jpg: Grass Valley selected KABELSCHLEPP hybrid series KC 0650 cable carriers featuring glass-fiber reinforced nylon side bands and cable-friendly aluminum frame stays.
U-Wagen_CloseUp1.jpg: Due to space constraints, two cable carrier systems are arranged in nested operating mode rotated 90 °.
U-Wagen_CloseUp5.jpg: Fully harnessed cable and hose carrier systems: view of the installed cable and hose package. Cables and hoses of various sizes are separated by a divider system.
U-Wagen.jpg: 40 ton technology: HDTV-media truck “OB Unit 6” built by Grass Valley and equipped with up to 25 cameras, a 4 layer-video mixer with 62 ports and an audio mixing console.
