Design Basics: Continuous-Flex Cables

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Design Basics sponsored by: 5. Ensure every cable has room to move freely during movement of the cable carrier. Be sure each cable has plenty of room to move while in operation. This will maximize the service life, and reduce risk of abrasion and other common cable failures, like we explored earlier in this guide. 6. Take the time to be sure that cables rest in the neutral axis of the cable carrier, especially while operating at the carrier's maximum bend radius. When the carrier is bent, there should be no tensile forces exerted on the cable. 7. If cables/hoses of varying diameters are being installed, utilize interior shelving or separators. This will prevent tangling. There are two easy cable distribution rules to follow to see if interior separation is needed. The first states that If the diameters of the cables, D1+D2 are greater than 1.2 x the inner height of the cable carrier, no separation between the two cables/hoses is necessary. If the diameters of cables D1+D2 are less than or equal to the inner height of the cable carrier, use vertical separators or horizontal shelf to prevent crossover/abrasion. More resilient material will gradually wear down the softer jacket, leading to failure. See the diagrams to the right for a visual of these rules. 8. Use strain relief at both ends of cables. There are a number of strain relief options, including mounting brackets, tie wrap plates, etc. Proper strain relief keeps the length of cable inside the carrier fixed at all times. In certain cases, strain relief may only be necessary at the moving end of the cable carrier.

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