Control cables for energy chains

People think control cables are boring, but they keep industry running worldwide. The control cable is the quintessential cable and usually has one green/yellow core for earth and many black cores for the signals. The special number of cores is due to the typical strand structure of the past. Cores used to be distributed in layers, so a certain number of cores was specified. Today, there are more robust ways of stranding. Since the cable handles signals from the usual alternating current network, it is normally designed in the 300V/500V voltage class. A shielded variant of this cable is also available if EMC conditions call for it.

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We rely on cores wound in bundles

Our control cables from 12 cores upwards have a special mechanical design to achieve a long service life in motion. We use so-called cores wound in bundles with a short pitch length.

But what does cores wound in bundles mean in concrete terms?

With cores wound in bundles, the cores are stranded in bundles depending on the number of cores and these bundles are stranded again. However, this very complex method is necessary in order to absorb the push/pull forces of the movement. These forces arise when the cable is in the radius. The core is compressed in the inner radius and elongated in the outer radius. We have developed the cores wound in bundles so that these forces do not put too much strain on a core, as this allows a core to constantly change its position within the cable. This equalises the forces. This is particularly important to prevent the so-called corkscrew effect, which often occurs over long distances.

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Seven reasons for our chainflex cable

In the course of cable developments over the past few decades, seven principles have evolved that ensure a high-quality, long-lasting cable in an e-chain. At igus, we call these findings the "seven reasons".

To the seven reasons

Here you have the opportunity to experience the CF6 control cable as a virtual, three-dimensional model

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Application example: chainflex control cable with cores wound in bundles

Cable in the forklift - a special challenge

For us, a very exotic application is the winding and unwinding of cables via plastic rollers on the forklift in the mast. This cable is pulled so that it does not jump off the reel when the vehicle is travelling. In addition, the deflection via these rollers puts extreme strain on the stranding. Years ago, our customer found out that this can lead to problems, and was very conscientious about testing it himself. We were allowed to take part in the customer's tests with our product and were able to convince them with the special cores wound in bundles, as the rope construction cancels out the forces on the core. Many years later, corkscrew in the cable and core breaks in this application have long been forgotten. If you also have challenges that your cable is not up to today, this could be the first step towards finding a solution together with us.

To the application report