Testing ensures long life on continuous-flex cables

When integrating machinery, OEMs and MROs look for long life on moving parts. To ensure its flexible cables are consistent with the mechanical requirements of the applications they will be used in, igus, East Providence, R.I., rigorously tests the durability of its Chainflex continuous-flex cables in its 19,000 ft² laboratory. The company performs around two-billion test cycles at more than 50 test machines every year.

“We’re always working to improve our processes and optimize the materials we use so that we can guarantee our cable carriers and cables perform well together”, says Don Nester, Chainflex Product Manager at igus’ North American subsidiary. “On top of that, we perform numerous application-related tests to guarantee our products are ready for almost any given application.”

Igus has been conducting the tests for more than 20 years. Endurance tests are supervised at over 50 different test stations and results are recorded by igus’ dedicated laboratory team. Cables are subjected to different types of mechanical stresses and monitored electrically. Afterwards, test results are analyzed and used to improve igus products.

Test setups include standard linear-axis tests involving various lengths of travel at different speeds. Tests can also be tailored specifically to individual customer applications. Igus’ test capabilities include linear travels up to 400 ft. Temperature profiles can be simulated in a 26 ft travel test chamber that ranges from –40 to 140°F. A robotic flex testing cell also tests the maximum lifetime of the CFROBOT series torsion-resistant robot cables on five different test robots.

When igus develops a test that is customized to a customer’s needs, that customer can follow the test’s progress in real-time via webcam, allowing them to see up-to-the-minute updates.

“From multiple conversations with our customers, we know that cable lifetime is a real priority”, says Nester. “So it’s our goal to offer the optimal cable to every customer without them ever having to sacrifice service life.”

igus inc.
www.igus.com