7 basic rules for a good cable

Depending on the number of cores and cross section, a free space forms in the core of a cable. If possible, this should be filled with a genuine core element (and not, as is often the case, with fillers or dummy cores made from waste materials). This provides secure support for the stranded structure above and prevents the stranding from migrating to the centre of the cable.

In several series of tests, a coordinated combination of individual wire diameter, pitch length and direction has proven to be the most bend-resistant solution in movement-optimised cables. Single wires that are too thin make for a very flexible cable, but have a strong tendency to kink.

The insulation materials must be designed in such a way that they do not stick together within the cable. The insulation also has the task of supporting the stranded individual wires of the conductor. For this purpose, only the highest quality, high-pressure extruded PVC or TPE materials are used, which have proven themselves in millions of kilometres of cores in e-chains® applications.

The stranded structure must be stranded with an optimised short pitch length around a strong core with high tensile strength. Due to the insulating materials used, it should nevertheless be flexible within the stranding defined. The cores wound in bundles should be used from 12 cores.

A gusset-filling extruded inner jacket is used instead of inexpensive fleeces, fillers or accessory fillers. This measure ensures that the stranded structure is guided securely in the longitudinal direction. In addition, the stranded structure cannot unravel or migrate. The inner jacket thus serves as a firm foundation for the shield.

The overall shield should be manufactured tightly with an optimised braiding angle over an extruded inner jacket. Loose, open braiding or even looping considerably reduces the electromagnetic compatibility protection and can fail particularly quickly due to shield wire breaks. A tight overall braided shield provides additional torsion protection for the stranded structure.

The PVC, PUR or TPE outer jacket can fulfil a wide range of requirements: from UV-resistant to flexible at low temperatures, oil-resistant to cost-optimised. But they should all have one thing in common: a jacket material must be highly abrasion-resistant, must not stick, must be flexible, but should also provide support. In any case, the jacket should also be extruded with pressure (gusset-filling).