What's new regarding cables and carriers?

Larry • KabelSchlepp: Cables, carriers, and related components have evolved over the years to accommodate ever-increasing demands for higher cycle speeds, longer life, and greater reliability. Specialized designs can address specific challenges such as clean room use, elimination of operating noise, and reduced installation costs. Innovations in materials and manufacturing processes include the use of nanotubes in plastics for greater strength, and electrostatic discharge for applications where explosion hazards exist. Processes such as simultaneous co-molding of different materials allow single-piece carrier links that have a rigid frame made of one material for high strength, and flexible crossbars made of another material for easy cable installation.

Kevin • Northwire: Other new technologies and materials in the cable world include in-process control devices (laser and x-ray technology), low smoke zero halogen and halogen-free flame retardant (HFFR) insulation and jacketing materials, and improved tensioning of primaries and cabled core during cable manufacturing. Improved shielding technology is also being used on connectors.

Joe • igus: Some of today's new tools make the process of specifying a cable carrier system much easier. For example, we offer an online product selector and cable carrier configurator. With the product selector, users can quickly select the right cable carriers or continuous-flex cables by simply entering a few application parameters. With the configurator, users are able to easily build a cable carrier with cables and internal separators online. CAD files, parts lists, and quote requests can all be quickly generated, saving engineers a lot of time.

EcoWire from AlphaWire is a new form of hook-up wire with up to 10 times better abrasion resistance, 40% lighter weight, and 45% smaller diameter than traditional PVC hook-up wire.

How can the right cables and carriers maximize productivity?

Joe • igus: Choosing the right cable carrier — and pairing it with appropriate cables for the application — is crucial. While steel cable carriers still dominate in some industries, such as on boom trucks and in the steel-working and mining industries, plastic carriers can replace steel in almost any application to maximize productivity. Plastic cable carriers have replaced steel on most types of automated machinery in recent years because they are lighter weight and enable a higher number of cycles, faster speeds, and increased production throughput.

Another way to avoid failure and downtime is to make sure the cables housed in the cable carrier are designed for continuous flexing. If a cable that can't handle high-flex environments is used in a dynamic application, loss of continuity, insulation damage, and jacket abrasion can result, leading to machine failures and downtime. Using a pre-harnessed cable carrier system can also maximize productivity. If users receive a cable carrier system ready to go right out of the box, there's no need to fumble with cables, attach connectors, or assemble separators, mounting brackets, and other accessories.

Larry • KabelSchlepp: Today there's an increasing trend for cable and carrier suppliers to offer bundled “total systems” that provide all necessary components, perfectly matched to the application and environment. By providing a complete system, manufacturers can reduce installation times and associated costs, while reducing the risk that any subcomponent might not be suitable for the application.

Tell us about some emerging technologies.

Kevin • Northwire: Many new and emerging materials are under development, such as carbon nanotube technology, alternatives to wire shielding, improved low smoke zero halogen materials, and renewable materials for use in polymer design. A lot of work is also going into improving the purity of the dielectric, detecting minute flaws in cable surface, and improving connectivity (soldering and shielding) to increase signal and data transmission speed and accuracy.

What about best practices regarding specification and sizing?

Northwire provided 6,000 ft of its Underwater Cable for a casino application within a water theater, where the cable controls and powers moving platforms and water jets. The specialized cable is designed for use in freshwater or saltwater as well as chemicals, solvents, and other fluids.

Dave • Alpha Wire: If the size of the cable is approaching the maximum size for the carrier, avoid the temptation to use a cable that might be just a bit too large for the carrier and instead use two separate cables. Understand the difference between a flexible cable (a cable where the property of being limp or flexible is a significant design feature) and a high-flex cable that is specifically designed for continuous flexing. Not all flexible cables are optimal for continuous flexing. The rated flex life of the cable should be commensurate with the application.

Larry • KabelSchlepp:

Don't overfill the cable carrier. As a rule of thumb, allow an additional 10% of the OD of buffer space for cables and an additional 20% of space for hoses. Overall, the maximum cavity fill should be no more than 60%.

Unspool the cables and allow them to relax to relieve any tension or twisting before installing them in the carrier.

Consider environmental factors such as exposure to heat, cold, radiation, UV, salt water, and corrosive chemicals, and specify accordingly.

Bend radius is very important when specifying a cable and carrier system. Select cables or hoses that have a minimum bend radius that will fit within the operating envelope and that are designed to withstand the stress of continuous flexing. Then make sure that the cable carrier's bend radius is equal to or larger than that of the largest cable.