Although a cable may be marketed as flexible, the only way to be certain it delivers the flexibility you require is through validated test data. In Parts 1 and 2 of our flexible-cable blog series, we explored the various classifications and designations used in modern industrial systems as well as the construction features that enable these cables to perform reliably in demanding applications. Our series concludes with a look at how flex-life testing can provide peace of mind during cable selection, and offers some questions to help lead the way to an ideal cable for your industrial application.

 
Flex-Life Testing Provides Certainty

Testing will predict the cable’s viability and reliability in a specific application, prevent unplanned downtime and reveal its real-world lifetime.

 
At SAB, we validate flexible cables by testing:

●     Bend cycles. Cables are subjected to a specified number of bending cycles per minute at defined bend radii under particular speeds and acceleration conditions. Then we reverse the motion, creating an additional hardship to ensure continuity. The cables are monitored for broken conductors, jacket damage or kinks. Most cables can withstand 8 to 10 million flex cycles while some SAB cables can achieve 20 million cycles.

●     Torsion cycles. Cables perform a specified number of twisting cycles per minute to verify reliable electrical output without kinks or damage to the jacket. SAB twists cables at 540° torsion angles in both directions. Most torsion cables can perform 5 million torsions on average, and some SAB torsion cables can exceed that figure.

●     Bend radius compliance. We test flexible cables to ensure compliance with relevant standards for minimum bending radius, which is a multiplier of the outer diameter.

●     Environmental stress. Cable materials are exposed to oils and chemicals, and subjected to tensile elongation testing to verify their structural integrity and long-term durability.

 

Let Application Requirements Drive Cable Selection

When specifying a cable, it’s not enough to ask, “Is this cable flexible?” Instead, let your application details guide you through these questions:

●     Is the application static or dynamic?

●     What type of motion: bending, torsion or both?

●     What is the required cycle life?

●     Has the cable been tested for its application?

 

Consulting with a connectivity and cable expert to evaluate these criteria and analyze actual test results will help you choose a cable with appropriate flexibility. This proactive approach avoids unforeseen equipment failures while maintaining long-term productivity and system availability.

 

For more information about cable flexibility, please download our white paper "Not all "Flexible Cables are Created Equal" .

For more information about cable testing, please see our blog "Extensive Testing Ensures Reliable Cables That Meet Your Expectations"