Caring for Cables

Caring for Cables

9 Steps for Specifying a Cable Carrier System

What is a cable carrier?

Unsupported short travel

Types of installation

 

Here is a step-by-step guide to specifying a cable carrier:

  1. Gather data: The first step in choosing a cable carrier is to gather all the necessary technical data prior to contacting a cable carrier vendor. This includes length of travel, what cables or hoses will be installed, the size of cables and hoses and how much they weigh, any environmental factors such as debris, heat or chemicals, and speed and acceleration.
  2. The largest cable or hose: The first question any reputable cable carrier manufacturer will ask is, “What is the largest cable or hose in your system?” This will determine the minimum size of the cable carrier. To this number, add proper clearance - 10% for cables and 20% for hoses - and the resulting dimension is the minimum inner height of the carrier.
  3. Style, style, style: Next, choose the style of carrier. Always choose a snap-open version whenever possible. This type of carrier allows access to cables with crossbars that snap open at any point along the carrier. If debris or other external conditions are an issue, the tube-style cable carrier replaces the crossbars with lids to fully enclose the carrier and provide complete cable protection. This style is especially useful in applications where woodchips, metal filings and other debris are present.With a split crossbar, simply press the conduit into the carrier to install and pull straight up to remove. For zipper-like removal of crossbars, the carrier has interconnected lids that are pulled back like a zipper, removing the top section of the carrier. The hinged crossbars are attached to the side links and are made of non-fiber, reinforced nylon to enable the hinge to flex. These designs minimize assembly and disassembly time. There also are modular cable carriers for heavy-duty, longer-travel applications. They are available with hinged crossbars that are opened on either the inner or outer radius, depending on which is preferable for the application, or with lids to make them into a tube for debris protection. Special cable carriers are available to meet a variety of application requirements. Some are: low-vibration or low-noise carriers, multi-axis carriers for robotic applications, “twister” chains for rotational movements, fully enclosed carriers for protection against metal chips and flying debris, and carriers with integrated wheels for longer travels and less wear.
  4. The environment:The environmental conditions of an application typically determine which type or style of carrier to use. If debris such as woodchips or metal shards are present, or if the application is in a dirty or contaminated area, an enclosed tube is ideal. An open crossbar carrier is lightweight and facilitates easy inspection and replacement of cables, whereas tube carriers offer removable lids for cable access. Also consider whether the application is underwater or comes in contact with liquids. 

    Note: Space restrictions Many applications have a space restriction that will affect the design and selection of the cable carrier system. It is imperative that the performance of the system is not compromised to meet these restrictions.Keep in mind things such as the camber of the carrier when determining how much height is available for the installation. Camber is the curve of the upper portion of the carrier along its unsupported length. Most cable carriers are manufactured with camber, but special, no camber carriers are usually available upon request. Be advised however, that carriers without camber do not have the same load-bearing capacity as those with camber.
Bend Radius

60*150 mm MT open type nylon flexible both side openable cable chain

 
Cable and hose packages
  • Strain-relieving core: The center of a cable should be filled with a genuine core center to protect the cable core structure above and prevent conductors from falling into the center.
  • Conductor structure: Medium to fine strand diameter is preferable.
  • Core insulation: Insulation materials must be friction-resistant to one another within the cable. Insulation must also protect the stranded wires of the conductor. High-quality PVC or TPE should be used.
  • Cable core: Conductors should be bundled into groups and cabled together in a single layer around the core, enabling pulling and compressing forces to cancel out any torsional forces. Special attention should be given to pitch length and pitch direction. Cables constructed in layers are not suitable for long-travel.
  • Inner jacket: A gusset-filling extruded inner jacket should be used instead of inexpensive fleece wrap or filler to ensure the cable structure is efficiently guided in the linear direction. This jacket design ensures the jacket maintains the integrity of the cable core.
  • Shield design: High-quality braided shields protect cables from electromagnetic interference and an optimized braid angle increases torsional stability. Each chainflex® cable has a shield with an optical coverage of 90%, which yields higher shield effective.
  • Outer jacket: Outer jackets must be UV-, abrasion-, and temperature-resistant and resistant to oils and chemicals. It also should not adhere and be flexible while providing support.
 
Cable carrier length:
  1. Use the following formula to determine the necessary cable carrier length:
  2. S = Maximum machine travel distance
    K = Curve length
    L K = Carrier length
    R = Bending Radius
    ∆M = Deviation from the center point
    L K = S/2 + K Use this formula if the fixed end is anything other than the center of travel
    L K = S/2 + ∆M + K
 
  • First, determine the acceleration force. Acceleration force is the force required to keep the cable carrier moving once it has started.
  • Acceleration Force (lb) = Total Weight lb (carrier and fill) x Acceleration ft/sec 2
  • Then determine the push force. Push force is the force required to get the cable carrier moving and overcome inertia.
  • Push Force (lb) = Total Weight x COF
  • Once those numbers are determined, calculate the force of the application by:
  • Acceleration Force + Push Force = Force Required
  • The force required must be less than the maximum force for the selected carrier. Cable carrier manufacturers typically do not publish the maximum force allowance for their products.
  • Interior separators or shelvesensure proper alignment of the cables within the carrier and prevent friction, tangling and corkscrewing. These are available in both vertical and horizontal implementations.
  • Mounting brackets are almost always required to attach the carrier system to the machine itself. Plastic or steel brackets made of a single piece are for smaller carriers. Others have aluminum bushings in the bracket to prevent damage when tightening the bolts. These can either pivot for standard applications or lock into place for vertical or side-mounted, gliding applications.
  • Guide troughs are available for long-travel applications
  • Rollers can be used for even longer-travel applications.
  • Extender crossbars enable the use of oversized conduits.
  • Strain relief Strain relief is another common accessory designed to keep cables in position at both ends of the carrier. Sometimes strain relief at just the moving end is sufficient, depending on the application, and hydraulic or other fluid hoses should only be strain relieved on the moving end.
  • Strain relief can consist of profile rails, clamps, tie wraps and tie wrap plates. Improper, or lack of, strain relief is a common cause of cable and hose failure. The strain relief clamps hold the cable in the neutral axis of the carrier. This prevents the cables from being pulled against the inner radius of the carrier or pushed against the outer radius of the carrier where it can be damaged or incur wear. While it may seem like an insignificant point, strain relief can often make - or break - the success of an application.

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