{"id":5636,"date":"2023-04-12T16:45:24","date_gmt":"2023-04-12T08:45:24","guid":{"rendered":"https:\/\/www.ray-tron.com\/?p=5636"},"modified":"2023-09-01T13:54:32","modified_gmt":"2023-09-01T05:54:32","slug":"ele5724","status":"publish","type":"post","link":"https:\/\/www.ray-tron.com\/en\/ele5724\/","title":{"rendered":"What is a flexible cable"},"content":{"rendered":"

Flexible cables, or \u201ccontinuous-flex\u201d cables, are cables specifically designed to handle the tight bend radii and physical stresses associated with mobile applications, such as within a cable carrier.<\/p>\n

Due to the increasing demands within automation technology in the 1980s, such as ever-increasing loads, moving cables guided within cable racks often failed, even if the cable racks themselves did not fail. In extreme cases, failures caused by "corkscrews" and broken cores brought entire production lines to a standstill, which was costly. Therefore, specialized, highly flexible cables were developed with unique properties to distinguish them from standard designs. These cables are sometimes called "chainable," "highly flexible," or "continuously flexible" cables.<\/p>\n

This higher level of flexibility means that the life of the cables in the cable carrier can be significantly extended. A normal cable can typically handle 50,000 cycles, but a dynamic cable can achieve between 1 and 3 million cycles.<\/p>\n

\"\"

structure<\/p>\n

Flexible cables can be divided into two types: the type where the conductors are twisted in layers within the cable, and the type where the conductors are bundled or braided.<\/p>\n

Layered twisting<\/p>\n

Layered stranding is easier to produce and therefore usually less expensive. The cable cores are firmly twisted, leaving relatively long layers around the center, and then wrapped in an extruded tubular sheath. In the case of shielded cables, the core is wrapped in fleece or aluminum foil.<\/p>\n

However, this type of construction means that during bending, as the cable core moves, the inner radius compresses and the outer radius stretches. At first, this works well because the material remains elastic enough, but material fatigue begins to set in, causing permanent deformation. The cable core moves and begins to form its own compression and tension areas, which can lead to a "corkscrew" shape and eventually cause the cable core to break.<\/p>\n

Bundling and twisting<\/p>\n

The unique cable construction technology weaves the conductors around a stretch-resistant core, rather than layering them, which is the second structure.<\/p>\n

The elimination of multiple layers ensures that each conductor has a uniform bend radius. At any point in the cable bend, the path of any core moves quickly from the inside of the cable to the outside. The result is that no core is compressed near the inside of the bend or stretched near the outside of the bend, which reduces overall stress. An outer jacket is still required to prevent the core from disintegrating. A pressure-filled jacket is preferred here, rather than a simple extruded jacket. This fills all of the sandwich around the core, ensuring that the core does not disintegrate. The resulting dynamic cable is typically stiffer than a standard cable, but can last longer in applications that require constant flexing.<\/p>\n

For use in cable carriers\/drag chains<\/p>\n

Flexible cables are a versatile material due to their many different applications. When flexible cables are used in construction, they often need to be protected with cable racks\/drag chains. This is not only for the health and safety of the workers, but also to protect the cable itself. If the cable is damaged, it is likely to result in expensive repairs. Likewise, if the cable is left in mid-air or running along the floor, the risk of injury increases.<\/p>","protected":false},"excerpt":{"rendered":"

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