Highflex Cables Boost Automation Efficiency in Production Lines

High-flex cables, also known as continuous flex or drag chain cables, represent a specialized cable category designed to withstand the rigorous demands of automated equipment. These cables excel in environments requiring frequent bending, twisting, and movement through innovative material selection, structural engineering, and manufacturing processes.

The development of high-flex cables parallels the rapid advancement of automation technology. During the 1980s, as industrial automation became more sophisticated, conventional cables proved inadequate for applications involving continuous movement in drag chain systems. Early iterations focused on enhanced materials and structural improvements to increase bend resistance. Modern high-flex cables now demonstrate superior performance across multiple parameters including abrasion resistance, torsion tolerance, chemical resistance, and oil resistance.

The fundamental design philosophy of high-flex cables focuses on stress distribution through several key mechanisms:

• Stress dispersion: Special conductor stranding techniques and insulation materials distribute bending stresses evenly
• Material flexibility: High-elasticity materials withstand repeated deformation without failure
• Structural integrity: Advanced construction methods maintain cable geometry during movement
• Friction reduction: Low-friction materials minimize wear during operation

High-flex cables incorporate several specialized elements:

Typically employing fine bare or tinned copper strands processed with specialized stranding techniques to enhance flexibility and fatigue resistance.

Utilizes durable elastomers such as TPE, PUR, or PVC selected for specific environmental challenges including abrasion, chemicals, or extreme temperatures.

Incorporates tinned copper braids or aluminum foil to maintain signal integrity in electromagnetically noisy environments.

Features abrasion-resistant outer layers of PUR, PVC, or TPE formulated for specific operational conditions.

Two primary construction methods dominate high-flex cable design:

Conventional layered designs offer cost-effective solutions for moderate flexing applications but may develop stress concentrations with intensive use.

Advanced bundled or braided architectures distribute mechanical stresses more evenly, significantly extending service life in high-cycle applications.

Key evaluation parameters include:

• Flex life (bend cycles to failure)
• Minimum bend radius
• Temperature range
• Voltage rating
• Chemical/abrasion resistance
• EMI shielding effectiveness

High-flex cables serve critical functions across multiple industries:

• Industrial robotics and automation systems
• CNC machine tools
• Material handling equipment
• Medical imaging systems
• Renewable energy installations
• Entertainment technology

Proper installation significantly impacts cable performance and longevity. Critical factors include:

• Maintaining specified bend radii
• Avoiding torsional stress
• Implementing appropriate strain relief
• Ensuring adequate cable management

Emerging trends in high-flex cable technology include:

• Enhanced flexibility for compact installations
• Improved environmental resistance
• Integrated condition monitoring capabilities
• Sustainable material alternatives
• Higher data transmission rates

Major certification programs ensure quality and safety:

• UL (Underwriters Laboratories)
• CE (Conformité Européenne)
• RoHS (Restriction of Hazardous Substances)
• VDE (Verband der Elektrotechnik)

As automation technology continues to advance, high-flex cables remain essential components for reliable operation across industrial and commercial applications. Proper selection and implementation of these specialized cables can significantly enhance system reliability while reducing maintenance requirements.