Signal and data cables with long service life for "E-Kart" research project

• What was needed: chainflex® cable
• Requirements: A completely new power cabling system was required, specifically a large number of data and control cables with maximum currents during recuperation of up to 100 amps
• Industry: Automotive
• Success for the customer: The cables were sponsored for the research project. The research team works with data and control cables that are tested in the in-house test laboratory for extreme loads in energy chain systems with many millions of double strokes, thus guaranteeing a long service life.

Since the start of the project, student teams have been working continuously on further development every semester. Starting with the conversion and rebuilding of the kart with electric motors, the development of a traction control system (ASR), a concept for the outer skin of the kart, the optimisation of the brakes, the construction of a camera mount on the kart, through to the road approval team. In March 2009, further student teams took on three new projects on the e-kart. One of these was dedicated to recovering braking energy. As with hybrid vehicles, the aim is to feed electrical energy back into the batteries during braking, thereby protecting the braking system and extending the possible journey time.
Another group of students set themselves the goal of replacing the installed starter batteries. A new battery technology was to be integrated. A concept for rapid charging of the four traction batteries with 4x25 amps achieved a full charge of the e-kart after approx. 2 hours. The third important aspect of the project was to integrate measurement technology into the e-kart. The measurements of the four battery voltages and the current of the batteries connected in series were to be recorded. A netbook was installed on the kart to store and output the measured values directly to the driver.
Due to the newly integrated batteries, the increased current of the chargers and the maximum currents during recuperation of up to 100 amps, the power cabling had to be completely rebuilt. In addition, the supply line to the chargers and the complete cabling for the measurement technology had to be created.

To realise the three new projects on the kart, the student groups needed a variety of control and data cables. These were sponsored by igus® for the e-kart. The various cable types for moving applications come from the chainflex® product portfolio, which offers a comprehensive selection for every area of application with control, bus, motor, data, measuring system, servo, special, hybrid and fibre optic cables. Data cables, such as those used in the E-Kart, convert information into voltage or current signals, which are often designed as 0 to 10 V or 4 to 20 mA signals.
All data cables from chainflex® are tested in the company's own test laboratory for extreme loads in energy chain systems with many millions of double strokes. The test parameters are high speeds, acceleration in different bend radius and travel distances. This enables us to offer a functional guarantee of up to 36 months for your data cables.
Due to their use in very different external conditions, data cables must be protected against many different influences. Depending on the requirements, chainflex® data cables can be selected as flame-retardant and/or halogen-free versions. Depending on the sheath material, medium to high oil resistance is also possible. You can use our online configurator to determine exactly which cable is right for you.