Tough And Flexible Power Cable | Znergy Cable

09 Mar.,2023


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Flexible cables, also known as continuous-flex cables, are cables that are designed to withstand the tight bending radii and physical stress of motion control applications. To set them from traditional designs, these incredibly flexible cables were created with distinctive features. These cables are also known as chain-compatible, high-flex, or continuous-flex cables.

A cable’s service life is extended when it has a higher amount of flexibility inside a cable carrier. A normal cable can typically handle 50,000 cycles, whereas a flexible cable can handle one to three million.

There are two types of flexible cables: those with stranded conductors inside the cable and those with bundled or braided conductors.

Stranding in layers is less expensive because it is easier to make. The cable cores are stranded tightly in multiple layers around the center and then encased in an extruded tube-shaped jacket. The cores of shielded cables are usually coated in fleece or foil.

This style of construction, on the other hand, means that as the cable core moves, the inner radius compresses and the outer radius stretches throughout the bending process. Because the material’s elasticity is still sufficient, this can operate well, but material fatigue can set in and produce irreversible deformations. When the cores move, they create their own compressing and stretching zones, which might result in a “corkscrew” shape and, eventually, core rupture. Instead of layering conductors, the other construction method includes braiding them around a tension-proof hub. The absence of multi-layers ensures a consistent bend radius across all conductors.

Every core’s path moves swiftly from the inside to the outside of the cable at any point where the cable flexes. As a result, no single core compresses or strains at the inside or outside of the bend, resulting in lower total stresses. To keep the cores from untwisting, an outer jacket is still required.A pressure-filled jacket fills all of the gussets surrounding the cores, preventing them from untwisting. The flexible cable that results is frequently stiffer than conventional cable, but it lasts longer in applications where it must constantly stretch.

A few basic characteristics are used to choose the proper flexible cable for an application. Determine the application type first. Is the cable going to be stationary or moving? If the latter, is the motion primarily flexing or does it include torsional motion? Is there a need for both flexing and torsion in the application? Different applications have cables that are specifically designed for them.

Znergy’s flexible power cables are ideal for systems that require large currents and flexibility, such as armored vehicles, tanks, radar systems, public transportation, automobiles, wind turbines, robotics, and ships. Flexible power cables are produced with extremely flexible conductors insulated with Special Compounds (ASC), halogen-free, or FEP materials for extreme conditions.

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