Damage to shielded cables and prevention methods
In the manufacturing process of the shielding layer, there are many correct or incorrect processes. One of the most important parameters is the braid angle of the shielding layer.
In cables used for drag chains, the load borne by the shielding layer of the outer diameter of the cable must be taken into consideration. Unreasonable braiding angles of the shielding layer will further increase the tension load and cause damage to the shielding layer. As a result, the shielding effect will be weakened, and when the sharp end of the cable pierces the wool fabric or foil gold material and touches the core wire, it may even cause a short circuit. Here, we recommend you a useful tip: If you strip off the insulating layer, you can easily push the shielding layer back into the sheath, but such a shielding layer cannot be applied to the energy supply system. Highly flexible cable. Of course, igus can provide direct solutions to these problems:
The braiding angle of the shielding layer determined through long-term experiments can effectively offset the tension, so it is very suitable for drag chains.
Due to the stable inner sheath, the shielding layer will not loosen and fail.
In the twisted wire structure, the shielding layer itself has anti-torsion performance.
The sheath is worn or damaged
Any defect in the internal structure is difficult to detect from the outside, but the problem of the sheath can be directly observed with the naked eye. The sheath is a layer of protection for the precise internal structure of the cable. This is why a sheath that is cracked, worn, and swelled is a very serious quality problem. In order to avoid such problems, igus provides cable sheaths of seven different materials for users to choose according to the corresponding working environment of their machinery.
Armored extruded sheath
Manufacturing processes and materials are also important factors that determine product quality. In some so-called cables suitable for drag chains, the sheath is usually tubular, so it cannot provide the necessary support for the stranded structure during the long-term bending process, so that the stranded structure is easy to split.
As a manufacturer of energy chain systems, igus has developed a armored extruded sheath.
This kind of sheath can ensure that the core wire will not loosen when the cable is in motion. The reason is that the sheath is squeezed through a particularly large pressure. It is like a guide groove, which guides the movement of the core wire and also supports it. So it is very suitable for drag chains.
Summarize the quality assurance of high-flex cables suitable for drag chains: Central stress-relief design; multi-bundle cable structure; armor-type extruded inner sheath in shielded cables; fully shielded insulated braided mesh; optimized shielding braid angle ; Armored extruded sheath.
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