During the development of our cables and wires, we thoroughly test each product in our test laboratories. In the third part of our series, HELUKABEL introduces you to the testing of cables in track systems.
Energy chains – also known as energy chains – are ideal for guiding and protecting electrical, hydraulic and pneumatic cables in moving machines and equipment. They are used in situations where machine parts move back and forth – for example in elevators, machine tools and in the control stations of high-bay warehouses. The guide ensures that the smallest permitted bending radius for the cables is not exceeded, thereby preventing damage.
Track cables are in constant motion – often continuously day and night – making rapid acceleration, tight bend radii and constant wear a constant challenge. There are many applications where cables in tracks must withstand millions of bend cycles without damage, while also being resistant to oil, heat and chemicals. High quality core insulation and sheathing materials are essential here to reduce the risk of abrasive wear, which could damage the cables and lead to expensive machine failure.
The HELUKABEL portfolio includes special cables for moving applications in energy chains. To ensure that they meet the stringent requirements of daily use, we subject them to extensive testing in our test laboratory in Windsbach, Germany. We have various test facilities with traverse paths ranging from 0.9 to 40 meters. With accelerations of up to 50 m/s², speeds of up to 10 m/s and different chain bending radii, we can realistically simulate various operating conditions. The aim of these tests is to prove that the copper wires, core insulations, stranding and outer sheaths withstand constantly changing bending stresses undamaged and thus meet our high quality standards.
Only cables that meet all our stringent requirements find their way into our product portfolio. That is why our track cables are HELUKABEL's contribution to ensuring that plants and machines can operate both cost-effectively and efficiently in the long term, even under tough conditions.
What specifically should you pay attention to when choosing a caterpillar cable?
There are several criteria: Firstly, the copper wires must be finely tinned, i.e. they must be class 5 conductors. The individual conductors must be tinned with the smallest possible laying length in order to optimise flexibility. The design of the sheathing and insulation materials must take into account the required movements and the relevant environmental conditions. It is also recommended to keep the number of cores to a minimum: if the number of cores increases, a special torsion process is required. This increases the diameter of the cable, which can lead to space problems in the energy chain. In addition, track cables must be designed to be as light as possible. The energy chain must carry its own weight as well as that of the cables in it. The lower the total weight, the greater the dynamic performance and therefore the less energy is required to get the system moving.
How are the cables aligned in a cable chain?
For optimum alignment, it is important to determine in advance exactly which cables and other components such as pneumatic and hydraulic hoses will be used and to select the energy chain accordingly. Cables and hoses should be placed loosely next to each other in the chambers of the dragline and ideally separated from each other using dividers. Maintaining a specified clearance between the cable and divider ensures that the cables can move freely. Symmetrical weight distribution in the energy chain helps with smooth operation. In addition, the cables in each section should all have the same sheathing material to prevent unnecessary wear.
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