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Proper cable protection/flex management/etc.

M

Michael

Jan 1, 1970
0
Hi there - I'm constantly dealing with cables breaking. I work in
robotics, so I am always stringing cables through joints and whatnot -
so these cables see constant flexing. Try as I might, though, no
matter how carefully I route cables, they always wear out.

Are there secrets to properly running cables? Perhaps is there a good
resource about this? I mean much of it is common sense - but I suspect
that there is much that I don't know - like how thick of insulation to
use, what kind of strain relief to use at connectors, etc.

Suggestions?

Thanks dudes,

-Michael
 
A

Adrian Jansen

Jan 1, 1970
0
Michael said:
Hi there - I'm constantly dealing with cables breaking. I work in
robotics, so I am always stringing cables through joints and whatnot -
so these cables see constant flexing. Try as I might, though, no
matter how carefully I route cables, they always wear out.

Are there secrets to properly running cables? Perhaps is there a good
resource about this? I mean much of it is common sense - but I suspect
that there is much that I don't know - like how thick of insulation to
use, what kind of strain relief to use at connectors, etc.

Suggestions?

Thanks dudes,

-Michael
Look for "Superflex" cable, which has soft insulation, and a large bunch
of *very* fine copper wire for the conductors. Often sold for test lead
cable and such.

--
Regards,

Adrian Jansen adrianjansen at internode dot on dot net
Design Engineer J & K Micro Systems
Microcomputer solutions for industrial control
Note reply address is invalid, convert address above to machine form.
 
C

Charles

Jan 1, 1970
0
Michael said:
Hi there - I'm constantly dealing with cables breaking. I work in
robotics, so I am always stringing cables through joints and whatnot -
so these cables see constant flexing. Try as I might, though, no
matter how carefully I route cables, they always wear out.

Are there secrets to properly running cables? Perhaps is there a good
resource about this?

Run the cables where flexing is minimized ... you probably already know that
.... but I had to say it ...
Use cables that use fine (small gage), braided conductors and shields.
Pay close attention to strain relief, cable support and abrasion points and
add bushings/sleeves when necessary.
Thick insulation can work against you.

I don't know of a good website about this but others might. GL!
 
B

Bill @ DSE Global

Jan 1, 1970
0
Run the cables where flexing is minimized ... you probably already know that
... but I had to say it ...
Use cables that use fine (small gage), braided conductors and shields.
Pay close attention to strain relief, cable support and abrasion points and
add bushings/sleeves when necessary.
Thick insulation can work against you.

I don't know of a good website about this but others might. GL!

Excellent cable source for hi-flex cable is Igus, check out:
www.igus.com
They cut to whatever length you want and are cheap, excellent support
too. You can call them up and ask for advice on the best cable to use.
Good luck!

Bill
 
W

whit3rd

Jan 1, 1970
0
Hi there - I'm constantly dealing with cables breaking. I work in
robotics, so I am always stringing cables through joints and whatnot -
so these cables see constant flexing.

Cable materials (metals and polymers) will tolerate flexure
indefinitely
if that doesn't exceed the elastic limit of the materials. So, keep
the
cables loose (to eliminate tension) and add in a few loops where you
have room (the bending of a loop is distributed over the entire length
of wire in the loop, NOT concentrated at one short segment). Take
the lesson of the coiled cord on a telephone handset; it rarely
breaks,
because each coil takes up a bit of flexure.

Also, use thin cables where possible, because a 1/4" cable bent around
a 1" radius has a lot bigger internal stresses than a 1/8" cable with
the same
bend. If you can remove the solid sheath from a cable, and replace it
with a
fabric (like polypropylene wire loom), your 1/4" sheathed cable
becomes
a bunch of 1/32" individual conductors. For bends without any twist,
a
printed-wiring assembly can be effective because the copper/kapton
sandwich
is again a very thin section; use a spiral of flex wiring for a tight
bend, because
it can flex ONCE to take the spiral shape without damage; subsequent
flexure changes that spiral shape only slightly.
 
J

JeffM

Jan 1, 1970
0
Michael said:
I'm constantly dealing with cables breaking
[...]these cables see constant flexing.
whit3rd said:
[lots of other good stuff snipped]
keep the cables loose (to eliminate tension)
and add in a few loops where you have room
(the bending of a loop is distributed over the entire length
of wire in the loop, NOT concentrated at one short segment).
Take the lesson of the coiled cord on a telephone handset;
it rarely breaks, because each coil takes up a bit of flexure.
Yup. If you have the space, coily cords are the gold standard.
2 other places where they are commonly used are guitar cords
and connectors from foil on glass doors/windows
over to the door/window frame (on places with burgler alarms).

Think how much traffic the front door of a prosperous business gets
....and do I have to mention what Rock-n-Roll musicians can do to stuff?
 
J

JosephKK

Jan 1, 1970
0
Charles [email protected] posted to sci.electronics.design:
Run the cables where flexing is minimized ... you probably already
know that ... but I had to say it ...
Use cables that use fine (small gage), braided conductors and
shields. Pay close attention to strain relief, cable support and
abrasion points and add bushings/sleeves when necessary.
Thick insulation can work against you.

I don't know of a good website about this but others might. GL!

I second the issue of strain relief, i have seen to many times where
careful strain relief dramatically improved operational life.
 
E

Eeyore

Jan 1, 1970
0
Michael said:
Hi there - I'm constantly dealing with cables breaking. I work in
robotics, so I am always stringing cables through joints and whatnot -
so these cables see constant flexing. Try as I might, though, no
matter how carefully I route cables, they always wear out.

Are there secrets to properly running cables? Perhaps is there a good
resource about this? I mean much of it is common sense - but I suspect
that there is much that I don't know - like how thick of insulation to
use, what kind of strain relief to use at connectors, etc.

Suggestions?

Cables 'wear out' wher they flex the most. Typically that'll often be right next
to the connector itself. Relieve your cables there first.

Graham
 
E

Ecnerwal

Jan 1, 1970
0
Michael said:
Suggestions?

Look at providing mechanical means to limit flex radius - run cables
inside a spring, hose, or innerduct type material, or use the "rolling
cable tray" type of cable control (typically seen on long rolling
assemblies - ie, stationary robots with internal parts that move
around), looks a bit like chain links in a box shape, with the box being
where the cables run.
 
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