Page 945 - ASEAN Chainflex Catalogue 2023

Example: tested,
tested, tested!
CF98 with < 4xd!
For users of very small energy supply chains with very small Test setup:
bend radii, the question of a suitable cable for very high cycle
life has come up many times in the past.
Test parameters
At bend radii of less than 5xd, copper quickly reaches its
physical limits, which necessitated the search for suitable Travel distance: S = 0.8m
substitute conductor materials or for a fundamentally different
conductor structure. Acceleration, approx.: a = 0.5m/s 2
Bend radius, approx.: 18 m
Many series of tests with a variety of conductor structures
and materials were performed in order to find out how cables
must be manufactured in order to be able to endure several
million bending operations in e-chains , even at bend radii of
®
less than 4xd.
938
Test 1: Test 2:
Inspection of four different cable designs
Two different cable designs were tested, and different core
numbers and cross-sections were selected in comparison
Four different cable designs have been analysed: with test 1:
Test item A - conductor in special conductor alloy
Test item A - conductor in special conductor alloy
Test item B - conductor same as test item A, but in copper
Test item B - conductor in copper
Test item C - conductor with braided structure
Test item D - conductor with layered construction In this case, test item B was manufactured completely identically
to test item A except for the conductor material. The test showed
This long-term inspection, which was carried out over a period
that not a single case of wire breakage could be detected for
of 2 years, provided the following results:
test item A even after 28 million double strokes. Test item B,
however, only achieved approx. 1.4 million double strokes
before complete destruction of the conductor was observed.
This test demonstrates that the alloy concept clearly surpasses
the life of the copper conductor by more than 19 times and
Horizontal, short travel distance Number of Cross d [mm] Test radius achieves these extraordinary results in the critical area of very
double strokes section small cross sections!
Test item A 47,434,277 7x0.20 5.8 3.1xd = 18 Number of Cross d [mm] Test radius
Test item B 450,000 7x0.20 5.6 3.2xd = 18 double strokes section
Speed, approx.: V = 1.5m/s Test item C 638,000 7x0.25 7.3 2.5xd = 18 Test item A 28,267,000 2x0.14 3.9 4.6xd = 18
Test item D 2,350,000 7x0.25 7.3 2.5xd = 18 Test item B 1,450,000 2x0.14 2.9 6.2xd = 18
Number of double strokes Number of double strokes
Test radius Test item A Test item B Test item C Test item D
3.1xd 3.2xd 2.5xd 2.5xd
Test radius Test item A Test item B
4.6xd 6.2xd
Conductivity of alloys
However, the outstanding mechanical properties of this alloy
also come with a reduced conductivity versus copper, but
this can be compensated for by means of slightly increased
cross-sections. This means that the cross-sections mentioned
in the catalogue meet the electrically defined cross-section
defined using the conductivity value. The conductor diameter
of the alloyed conductor increases slightly compared to the
conductor diameter of a copper conductor.
This compromise results in a 10% greater external diameter
for the CF98 series versus a comparable CF9 type, although
the service life differences between the CF98 versus the CF9
speak for themselves and increase by a multiple factor in
comparison with other so-called chain-suitable cables.
As in the case of the CF9 series, further characteristics of the
chainflex CF98 include the highly abrasion-resistant, gusset-
®
filling extruded TPE outer jacket, the oil resistance and the UV
resistance as well as the absence of any PVC and halogen
compounds.
In application areas with minimum space but which demand
a large number of strokes, the igus cable offers an increased
®
degree of operational safety and reliability. Relevant application
areas are in the: semiconductor and component parts
industry, automation sector as well as the automotive and
banking sector. New application possibilities can also be
found in automatic doors for motor vehicles and trains as
Product information CF98 well as in automatic food and self-service machines, and in
Page 134 the packaging industry.
939