Trailing cables usually have a C-screen, a tightly braided metal braid that is particularly resistant to bending. © Helucable

The cores are at the heart of every electrical cable. In cable drag chains, stranded conductors are used almost exclusively - i.e. conductors made of many fine copper wires, typically of conductor class 6. This particularly fine-stranded design enables high flexibility and is significantly more resistant to repeated bending stress than coarser strands. The quality of the core insulation also plays a key role. It must be abrasion-resistant, temperature-resistant and electrically resilient in order to protect the core permanently.

Stranding:

The way in which the individual cores are arranged within the cable has a significant influence on their bending capacity. A short lay length is particularly suitable for stranding, i.e. a tight twist of the cores around a central, tensile element. This ensures an even distribution of the tensile and compressive forces acting on the cable with every movement. Bundle stranding is recommended for very high loads. Here, several groups of cores are combined into bundles that wind together around the cable core. This design increases the service life, even if it requires a little more installation space.

Shielding:

In increasingly digitalized industrial environments, electromagnetic compatibility is a decisive factor. Effective shielding is necessary to prevent interference from neighboring cables or devices. The C-shield has proven itself here - a tightly braided metal mesh that is particularly resistant to bending. The braiding angle should be as flat as possible in order to optimally adapt to the movements of the cable.

Jacket material:

The service life of a cable in the chain results from the perfect interaction of several components. © Helucable

The outer sheath of a cable protects against abrasion, chemicals, oils and thermal influences. Materials such as PUR and TPE have proven particularly effective here. They offer high abrasion resistance and are also available in halogen-free and flame-retardant versions. Gusset-filling extrusion is particularly suitable for drag chain cables. The jacket is applied under pressure so that the plastic fills all gaps and firmly encloses the cores. This significantly increases the mechanical stability, but makes stripping more difficult - a challenge that Helukabel solves with an integrated ripcord, for example.

Standards and tests:

In addition to mechanical load capacity, cables must also comply with all relevant standards - whether DIN VDE, EN or UL. However, traditional standardization does not take sufficient account of the application in cable carriers. This is why manufacturers' own test procedures are crucial. Helukabel tests its cables under real conditions for millions of bending cycles, chemical influences and thermal loads. This ensures that the products can actually withstand the tough requirements in the field.

Systems thinking ensures process stability

An often underestimated success factor is the coordination of all system components. Cables that are optimally matched to the chain used minimize friction, vibrations and therefore wear, and they reduce potential sources of error. Manufacturers such as Helukabel, who develop and produce both cable drag chains and the associated cables, offer system solutions from a single source that can be individually configured and, if required, delivered pre-assembled and ready for connection.

Production managers, maintenance engineers and machine developers benefit from a well-founded selection of the right drag chain cable - tailored to the specific requirements. A holistic approach not only saves follow-up costs due to breakdowns or maintenance, but also increases planning reliability. Those who also rely on pre-assembled system solutions speed up installation and reduce the error rate in the field.

SPS, Hall 2, Stand 230/231