A critical decision: cables for dynamic applications
In today's sophisticated machines, the need for moving power and data supply is increasingly common. But, if safe and reliable operation is to be achieved, choosing the correct cable for these applications is a critical decision. Justin Leonard looks at the factors that must be considered and explains why standard cables are unsuitable.In a dynamic application - that is, an application where a cable is used to connect moving parts of a machine - cables may have to move backwards and forwards, in a rolling loop or even with a twisting motion. In today's high performance machines, these movements typically take place at high speed and it is common for them to be repeated thousands or even millions of times in a short timescale.
Standard cables are totally unsuited to this type of application. They have a very simple construction where each of their copper cores is made up of a small number of relatively large conductor strands. When cables of this type are subjected to repeated bending at a small bend radius, the copper strands making up each core 'work harden', become increasingly brittle and then break.
The same process can easily be demonstrated by bending an ordinary paper clip back and forth. Initially, it is flexible and bends easily, but after a short time it 'work hardens' and breaks. The breaking of conductor cores because of work hardening is a very common failure mode, usually leading to intermittent signals and data or shorting. There are other modes of failure when an unsuitable type of cable is used in a dynamic application.
In multicore cables, the cores are always twisted together in layers and in standard cables this twist has a long pitch. This means that when the cable bends, the inner cores are compressed while the outer cores are stretched. After a time, this process forces the cable to take up a corkscrew shape which, in effect, shortens it, and often pulls the cores out of their terminations or connectors. The deformed cable may also form loops that get trapped in the carrier or in machine parts, damaging the outer jacket and exposing the core conductors.
A third failure mode occurs when the cores untwist under the outer jacket of the cable, due to the forces described above. On a standard cable, this outer jacket is a simple tubular extrusion. This is beneficial when terminating the cable, because the jacket does not grip the cores tightly and is, therefore, easy to strip back. In dynamic applications, however, the jacket has the important role of stopping the cores from untwisting, and even with dummy filler cores or strings (a common trick used to pack out the inner construction on a standard cable) a simple tubular jacket is not effective in doing this. The result is that the cores untwist within the jacket, and this can be seen as bulges along the length of the cable. Ultimately, the outer jacket will burst under the strain. With shielded cables, there's yet another problem. The braiding angle of the shield is usually steep, but this means that the braid has a tendency to open up and create gaps in the shielding when the cable is flexed; this leads to a worse quality of EMC protection. Also because of the steep angle, the braid will be extended and compressed under bending leading to work harden and fracture. This leaves sharp ends that can pierce the insulation of the inner cores leading to earth faults, or cut into the outer jacket starting a split.
So much for the shortcomings of standard cables in dynamic applications, but how do cables specifically designed for the applications - 'dynamic' cables - overcome these problems? First of all, the copper cores are more finely stranded. However, it is a common misconception that the finer the strand the better; the strand size must actually be optimised for maximum flexibility This type of construction reduces the risk of work hardening and core fractures, and can be used to give even large core high-current motor cables the flexibility needed for reliable operation in dynamic applications.
Next, in a dynamic cable, the cores are twisted with a much shorter pitch and, in multicore cables, the cores are braided and bundled wherever possible. This means that the path of the core takes it from the outside of the cable to the inside and back again over a very short distance. Because this distance is so short, the compression and tension stresses experienced by the core, when the cable is flexed, cancel each other out to a large extent, which means that the overall level of stress on the cores is greatly reduced.
Dynamic cables still rely on the outer jacket to prevent the cores from untwisting, but instead of a plain extruded jacket, a good dynamic cable will have a pressure-filled jacket. This fills all of the space around the cores (meaning dummy cores or strings are not needed) and ensures that they cannot untwist.
In good quality dynamic cables where EMC shielding is required, this will be of the braided type rather than wound foil, and it will have a shallow braid angle to prevent gaps opening up as the cable flexes, which would reduce the effectiveness of the shielding. The shallow angle reduces stress on the strands, whose sizes will also have been chosen to maximise flexibility, while minimising the risk of work hardening.
Because of their special construction, dynamic cables often feel stiffer than their standard counterparts. This shows that the myth suggesting that the cables most suitable for dynamic applications are the most flexible is not only wrong but also misleading. A rough and ready test to determine whether or not a cable is properly constructed for dynamic applications is to bend it tightly. A good dynamic cable will return immediately to its original shape when released, but other cables will tend to retain a kink.
We have already seen why it is essential to use dynamic cables in dynamic applications if safety and reliability are to be assured, but it is also necessary to choose the right dynamic cable for the task in hand. The information needed to make this choice falls into three areas - electrical, mechanical and environmental.
The electrical information needed is principally the number of cores required and their cross section, and whether or not shielding is needed. The cross section will depend on the current the cable is required to carry and, particularly for longer cables, the maximum permissible voltage drop. If the cables are being used for data rather than power, it will also be necessary to take into account the type of communications protocol being used.
The dominant factor is the minimum bend radius that the cable will have to adopt, which will typically match the bend radius of the energy chain or other articulated cable support.
The minimum bend radius for a specific cable is usually expressed as factor that is a multiple of the cable diameter. For example, a 25mm diameter cable with a dynamic radius factor of 10 can withstand bending at a minimum radius of 250mm. It is very important when working with these figures to be absolutely certain that the factor used is applicable for repeated dynamic use - the factor for static bending is likely to be much lower and, if it used in dynamic applications, early cable failure is likely to occur.
The dynamic bend radius factor for a good dynamic cable should always be accompanied by the guaranteed minimum life of the cable, expressed in millions of cycles, when that factor is used. Igus Chainflex cables are, for example, designed for 10 million cycles at the factors quoted by the company. For most types of dynamic cable, the dynamic bend factor is typically around 10, but it is worth noting that newer cables with dynamic bend factors as low as 4 are now being introduced for some applications. Among the other mechanical considerations are the travel length, speed and acceleration. The higher these are, the more strain will be placed on the cable.
Environmental questions that need to be answered include, for example, is the cable exposed to direct sunlight or other UV sources? Is it subject to caustic washdown or exposure to oils, solvents and dirt? What is the required operating temperature range? The answers to these questions will principally determine the type of material used for the cable outer jacket.
The last step in getting the best from dynamic cables is ensuring that they are installed correctly. Almost always, they will require some form of support and articulated carriers, for example those in the igus energy chain range provide a versatile and convenient option. The cables must, of course, be fitted properly within the chain with particular attention given to the provision of strain relief. This is usually achieved by the use of saddle clamps, but the clamps chosen must, once again, be suitable for dynamic applications where the forces they have to withstand are many times higher than those experienced in static cable systems.
Copper cables provide a versatile and convenient solution for providing power and data connections to moving parts of machines. Provided that genuine dynamic cables are used and that they are selected and installed correctly, solutions of this type are safe, reliable and cost effective. However, as this article has made clear, any attempt to cut corners or trim budgets by using standard cables is doomed to failure, and will without doubt lead to inconvenience and ultimately higher costs.
The conclusion is, therefore, simple. For dynamic applications, use good quality dynamic cables from a reputable supplier that can provide dependable advice and guidance on getting the best from them.
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- Electric vehicle charging points drive growth in cable management systems
- Stainless steel cable carrier proves successful under extreme conditions
- Intelligent maintenance with Igus plastics
- Igus opens online shop for connectors
- Move high loads easily with lube-free ball transfer units
- New oil-free drum motor for applications in the food industry
- Simplified cable entry with better ingress protection against liquids
- New plastic clamp concept from Igus for triflex R energy chains on cobots
- Keep equipment moving in freezing conditions
- Harting features connectivity and automation solutions for Integrated Industry at the Smart Factory Expo 2018
- Stäubli upgrades high current connector system
- Powering ahead with a new cable entry system
- Reliable energy supply for exploring the sun
- Intelligent cables detect the need for maintenance
- Energy chains and cables breathe life into lift bridge
- Sturdy, dirt-resistant plastic drag chains
- Monitoring the status of energy chains and cables with one module
- Drag chains feature innovative divider system
- Two become one: hybrid bus cables tried and tested
- Connectors suit harsh environments
- Rotatable connections from Lemo
- High-end chainflex series with alloy conductor and TPE outer jacket for bend radii of 4xd
- Cable test results letting users down in real world applications
- Process wiring – the benefit of being well connected
- Robust metal docking frame for easy connections
- New generation of low-noise energy chains from Igus for extreme dynamics
- RS adds robust and high-specification industrial micro-miniature connectors
- Easy clean hygienic energy chains for food applications
- Cable entries made simple with Conta-Clip KDSClick
- PushPull interface saves on assembly time
- Understanding the DESINA cable colour coding scheme
- Igus medium voltage cable for long-travel crane installations
- Market leaders collaborate on new M12 push-pull standard
- Modular plug-in connectors in snap-in frames
- An innovative approach to corrugated tubing
- Igus embeds intelligence into motion plastics to increase plant availability
- EasyTrax quick opener now in new dimensions
- Fast data acquisition for robots
- To guide and protect
- Cable-to-cable hood
- One metre in less than a second
- Chain reaction brings flexibility
- Smart plastics from Igus on show at Northern Manufacturing
- Embedding intelligence into motion plastics
- RS Components announces global distribution agreement with Fischer Connectors
- Testing cable carriers in realistic situations
- Automated metal-finishing benefits from Igus energy cable management
- Igus receives the ten thousandth readycable order from robotics company
- Automated metal-finishing benefits from Igus energy cable management
- Igus combines readychain with connector unit
- Harting preLink now in a Han 3A housing
- Igus invites submissions for energy chain application awards
- Connector is key to versatile interfacing for Peak Production
- Igus celebrates 25 years of chainflex
- Lightweight and versatile alternative to corrugated tube
- 3,200 assembled cables: configurable online and delivered from 24 hours
- Energy chains help keep frost at bay
- Igus introduces lightweight, easy-to-install vertical energy chain system
- e-spool power makes light work for lighting beams
- Real-world example of the new igus e-spool power
- RS Components increases stock of Alpha Wire product lines
- Quick installation with Igus zipper
- Industrial Ethernet switches with Power over Ethernet Plus (PoE+) power transfer
- Understanding UL
- CAT 5, 6, 6A and 7 Ethernet cable standards supported for energy chains
- New braided sleeving provides simple EMC screening
- Magnetic adapter keeps energy chains on track
- Fast cable selection, and dispatch within 24 hours
- Rugged DIN 41612 connectors offer space-saving benefits
- Cable protection at your fingertips with new flexicon app
- Slimline M12 connector with rapid termination technology
- Han 3A housing offers versatile mounting possibilities
- Cable termination technology with enhanced reliability
- Flexible cable carriers for reliable robotic automation
- Highest-density module added to Harting Han-Modular connector family
- Northern Connectors named Harting Distributor of the Year for the sixth time
- Harting features new connector ranges and contract manufacturing capabilities
- Robust connector housing for extreme requirements
- Connect and go with the new readychain speed from Igus
- RJ45 connectors for fire-resistant data cables in railway applications
- Robust connector offers reduced maintenance costs for outdoor theme park installations
- Fully sealed - New cleanroom chain from igus with ISO Class 1
- New tools for safe and simple assembly of industrial connectors
- Panel feed-through aids installation of PushPull connectors
- Cable carrying in demanding offshore applications
- Igus energy chains tame the tide
- Flexicon extends hazardous area range with new fast fit increased safety fitting
- Robust communications interface for rail and harsh industrial applications
- Secure cables in e-chains quickly and easily
- Cable carriers now with additional inner widths
- Cables for tasks with lower cycle requirements
- Easy to install field plugs offer reliable connections
- Plastic connector hood offers flexible housing solution
- igus' chainflex cables beat standard cables in dynamic applications
- Protecting power for subsea remotely operated vehicle
- Igus e-spool provides power and data in all directions
- New and improved igus chainflex cables reduce assembly times by 30%
- igus awards firm with a UK vector award for floating pontoon application
- E-chains provide electrical power and data supply for Rubber Tyred Gantry cranes
- Connectors meet intrinsic safety requirements for use in potentially explosive areas
- Flexible cables get DNV GL approval for use in maritime applications
- Full speed on the data highway
- Pop-open e-chain provides easy access for cables
- Flexible conduit
- Wimbledon's centre court roof glides safely with energy chains
- Easy assembly with readychain speed from igus
- igus sales engineers now all CSCS Certified
- Faster searching, faster assembly and faster purchasing of igus readycables
- Han connectors with RFID technology offer added value
- Harting enhances M12 connector family with "press and go" and outdoor versions
- Protecting fully automated spectrometer for climate research
- E2 micro e-chains are small, light and even stronger
- Han Hood Link speeds cable-to-cable connection
- Highly sensitive and really tough
- Light e-chain solution for large hoses and cables
- Pluggable feed-through housing eases cable installation in industrial environments
- Latest energy chains and bearings solutions at ABTT 2014
- Energy chain guide system, enclosed for safe operation, is now even bigger
- Up to 36 month guarantee on igus chainlfex cables delivers predictable safety
- Harting at Drives and Controls 2014
- Connector family extended with robust M12 module for applications at up to 10 Gbit/s
- High-temperature connectors function in environments up to 200°C
- Readychain cables are always secure
- Online technical data sheets now available for over 1,100 chainflex cables
- Easy and sealed servo motor connections
- Slimline M12 connector for gigabit Ethernet applications
- Harting connector provides space-saving interface with field assembly
- igus' energy chain is always delivered in less than 10 days and ready to install
- Standard LC fibre-optic connector module added to Harting's Han-Modular series
- Connectivity for the smart network infrastructure
- Flexicon sponsors 'Best of British' MotoGP Team
- Flexible conduits protect world's first intercontinental sea tunnel
- Configuring a cable in less than 3 minutes? With igus you can
- Power supply and encoder cable in a single-cable solution
- Flexicon announces growing team
- Igus exhibits compact readychain delivery system and fully-assembled linear drives at Southern Manufacturing
- CFRIP from igus now extends to over 230 chainflex cable types
- Wanted: innovative energy chain applications
- Light weight and reliable system for a variety of robotic applications
- Cables in less than 24 hours with Igus readycable
- New e-spool energy chain variants provide robust solution for routing multiple cables in small spaces
- Custom chainflex cables available in just three weeks
- Managing cables through linear and rotary movement
- Quick and easy to install guide trough for long travels of energy chain
- Quality, safety and expertise
- Assembly tools dramatically cut energy chain installation time
- New low cost roller energy chain and guiding trough
- Open guide system for energy chains is simple yet effective
- Circular connector range offers compact, customised solution including rapid locking for drive systems
- Cables deliver high performance in specialist applications
- igus NFPA 79-2012 compliant chainflex cables for dynamic applications
- New Polyurethane Coated Blue Flexible Conduit offers Low Temperature Performance
- Reduce cable strip back time by up to 50%
- Electrically conductive energy chains available within 24 hours
- Investigating distant galaxies with help from energy chain
- Additions to extensive cable range
- Fast fit flexible conduit fitting range extended
- Increase energy efficiency with green energy chains
- Industrial connector module offers high-voltage transmission with minimum space requirement
- Flexicon on track for Innotrans
- Secure cabling system based on Harting's Ha-VIS preLink technology
- Custom bodies offer new flexibility for M12 circuit board connectors
- New additions to Han-Modular industrial connector system
- Cost-effective emergency stop safety mechanism for cable management
- Cutting cable stripping time in half
- Cost-effective, flexible linear guide rail requires no maintenance
- Easily import igus chainflex flexible cables into EPLAN
- Tightly sealed with igus RX energy tubes
- New design of energy chain is up to 37% lighter
- Energy chains supply power on 117m ride
- igus c-chain for continuous movement
- Guide trough assembly made simple with igus
- Why you need an igus energy chain
- Why you need igus chainflex cables
- Taking plastics offshore
- Assembly tools for opening and closing energy chains in one go
- Energy Chain guide system for vertical movement eliminates need for troughs
- Quiet and reliable cable carrying for distances up to 800m
- Pre-assembled Energy Chain system delivered and installed onsite
- Control cables for energy chains now available ex-stock with 600V rating according to UL
- Faster without wasted movements
- An active retraction mechanism is now available for the ROBOTRAX
- CC-Link-compatible cable for energy chains from igus
- Universal bus fibre optic cable allows tight bend radius without compromising attenuation characteristics
- First GigE cable for energy chains
- Innovations in energy and data supply for robots
- Nine advantages for the price of one
- Profile roller energy chain P4 for fast, quiet movement
- RWTH Aachen tests vibration behaviour of energy chains
- The largest plastic energy chain in the world
- Triflex RS for compact cable guidance
- Sturdiness and flexibility in the same chain system
- Cable protection on the world's highest railway
- Cable carriers key at Bournemouth auditorium
- Cables for dynamic applications