Cable drag chains&#;also referred to as cable chains, cable carriers, cable track, and energy chains&#;are flexible hollow structures used to guide, support, and protect cables, hoses, and hydraulic lines when in motion. Industry professionals use them to prevent cables & hoses from tangling up or incurring damage during machine motion, both of which can cause accidents and contribute to downtime.
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Materials Used in Cable Drag Chains
Depending on the requirements and restrictions of the application, manufacturers use steel or plastic to make cable drag chains. Both materials offer different advantageous characteristics that make them suitable for different applications.
Steel & Metallic Components
Since their introduction by Tsubaki-KabelSchlepp® in the s, cable drag chains have employed steel as a primary construction material. To this day, it continues to be the material of choice for industrial applications due to its high tensile strength and temperature resistance.
Types of steel commonly used in cable drag chains include:
Stainless steel for increased environmental resistance along with heavy load carrying capacity.
Zinc-plated steel for traditional applications requiring heavy load carrying capacity.
Hybrid (metallic & nylon) for applications requiring design flexibility along with higher speeds and acceleration.
High-Performance Plastics
During the early s, manufacturers began using plastic&#;specifically polypropylene (PP)&#;for cable drag chains. Nowadays, plastic drag chains are as prevalent as steel ones and offer unique advantages for certain applications. Unlike many of the competitors, Tsubaki-KabelSchlepp® knows that every cable track application is different and the only way to properly provide the best possible protection for the cables and hose that the Tsubaki-KabelSchlepp® drag chain is carrying is to offer a full selection of materials, no one material is perfect for every application. In additional to offer the widest selection of drag chain materials, Tsubaki-KabelSchlepp® is also capable of manufacturing custom tracks when the application dictates this to be the best course of action.
Some of the specialized plastics employed in cable drag chains include:
Chip repellent materials that protect against flying metal chips as hot as 1,500° F
Cleanroom materials that do not create any dust or debris, making them suitable for use in applications that need super clean environments (e.g., semiconductor manufacturing)
Electrostatic discharging materials for sensitive electronic device manufacturing
Flame retardant materials for environments with combustible materials
Magnetically detectable materials whose fragments can be detected by metal sensors, making them suitable for operations requiring minimal product contamination (e.g., food processing)
Types of Cables Used in Drag Chains
Drag chains are used to guide, support, and protect a variety of constant flex cables and hoses, such as:
Bio-oil and microbial-resistant cables are resistant to abrasion and biofuels. They are environmentally friendly since they are made of recyclable materials.
Data cables are good for operating between -40° to 70° C.
PUR (polyurethane) cables have an operating temperature range of -20° to 80° C for flexing cables or -40° to 80° C for fixed cables.
PVC (Polyvinyl Chloride) cables operate between -10° to 80° C. They are flexible, number coded drag chains with good oil resistance and meter marking.
Applications of Cable Drag Chains
Drag chains are available in a wide range of designs to suit different applications. Functionally, they can be grouped into two categories:
Linear: moving in a straight line for distances less than one meter to more than 100 meters
Circular (or rotary): moving in circular arcs
Additionally, they can be classified by application:
Standard carriers have a simple design that allows quick installation of cables.
Advanced carriers have variable chain widths and more separation options than standard ones.
Extreme carriers are typically made from steel or stainless steel to suit harsh environments.
Carriers for 3D applications use rotational or swivel type movements in multiple dimensions.
Typical applications for cable drag chains include use in the following:
Port Cranes
Green energy systems
Machine tools
Process and automation equipment
Vehicle transporters and washing systems
Quality Drag Chains: Tsubaki-KabelSchlepp®
U.S. Tsubaki, a subsidiary of Tsubakimoto Chain Company, is an ISO certified company that manufactures high-quality power transmission, motion control, and bulk material handling equipment, including drag chains under the Tsubaki-KabelSchlepp® brand. To learn more about our product offerings, visit our Tsubaki-KabelSchlepp® cable carriers page. Contact us today for assistance choosing one that meets your requirements.
Cable Drag Chain: 4 Points to Guide You Choose
Currently, a cable drag chain is one of the most unappreciated facets of electrical wiring. The fact that most of people are clueless regarding cable drag chains is absolutely surprising. Recently, the world has witnessed immense industrial growth.
The industrial environment is characterised by vast adverse conditions. In such an environment, electrical cables need to be covered and protected to achieve maximum durability. That being said, you cannot use any type of electrical wire on a drag chain. Which is the most ideal drag chain cable?
Cables in a drag chain are constantly subjected to fast movements, uneven pull and twisting, and exposure to corrosive industrial chemicals. You need to choose a special type of cable that can withstand such conditions. Logically, you need a highly flexible cable drag chain wire.
However, the cables flexibility is not the only thing you need to consider. For an untrained individual, it is quite challenging to choose the right cable drag chain wire. Fortunately, by the time you finish going through this post, you will be well-equipped to make the right choices. All you need to do is go through this free article word for word and grasp all the valuable information.
1. What Is Cable Drag Chain?
Drag chains are used in a wide array of industrial applications. Some of the most common applications include industrial robots, machine tools, automation machinery, vehicle transporters, and cranes, to name a few. Essentially, a cable drag chain supports and protects moving cables. What cables are these and why do they need protection?
Cables used in an industrial environment are often in a mess and are constantly subjected to constant uneven pull and winding. Moreover, the cables are often exposed to harmful oil and corrosive chemicals. Can you visualize what would happen if such cables did not have any protection? Logically, without protection the cables will need persistent replacements due to repeated damages. An electrical cable drag chain offers an effective shield against such adverse conditions. However, the protection offered by a cable drag chain is not adequate in itself.
It is often advisable to use a specific cable drag chain wire that is suited for such high stress situations. It is best to use a flexible drag chain wire because it can withstand the uneven pulls and twists associated with industrial applications. Still, that is not the only thing you need to consider. Here are some things that you need to consider when choosing a suitable cable for a drag chain;
Your cable choice should have a tensile center
Your cable choice should have a stranded thin conductor for maximum flexibility
The insulation material should not stick to each other, must have an inner sheath and a tightly braided shielding layer.
2. How to Design Cable Drag Chain?
Do you intend to design your own Cable drag Chain? The process of designing one is complex and time consuming. It would be best to order a custom-made drag chain that suits your specific needs rather than attempting to design one. There are several cable drag chain manufactures that offer custom services. That being said, there is no harm in knowing how to design a drag chain.
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First, you need to understand that drag chains are mechanical systems whose sole purpose is to shield different cables in dynamic motion applications. A robot cable is an excellent example of a cable that needs such protection. Logically, a drag chain cable design is undertaken based on the specific application needs. What do I mean?
You need to ascertain inner cable chain space that suits your specific application. Simply put, you need a drag chain that provides adequate space for your cable drag chain wire. To guarantee proper cable functioning and safeguard the cables in the chain system, you need to determine the appropriate chain sizes. Chain sizes tend to vary depending on the intended applications. It is advisable to cable drag size chart when attempting to pick out a size that suits your specific applications.
There are several cable chain types. Each type is differentiated by the material used in its manufacture, its speed, acceleration, and several other factors. Currently, nylon cable drag chain and steel cable drag chain are the most common types. Nylon-type cable drag chain is ideal for heavy duty applications.
3. Where to Buy a Cable Drag Chain?
There are several entities where you can buy a drag chain. You can simply order one that suits your specific needs from a trusted manufacturer. Alternately, you can search for drag chain cable suppliers near you on your Google search engine. I am sure that there are several suppliers who sell drag chain cables within your locality. However, it is not advisable to just buy from the first manufacturer or supplier that just pops up in your radar. You need to carefully consider the quality of the cable drag chain that you intend to buy and whether it suits your specific needs.
At ZW cable, we strive for excellence in whatever product we manufacture. With over a decade of experience and a fully dedicated team of technicians, we guarantee that we can deliver the best product for you. So, why shouldn&#;t you buy a drag chain cable from us at an affordable price?
4. How to Choose a Cable Drag Chain?
Like ordinary electrical cables and accessories, a cable drag chain is not one-fits-all. The appropriate choice is entirely dependent on an individual&#;s intended application. As I mentioned earlier, the chain type and the cable type you intend to fit on the chain is critical in cable design. Well, the same goes when choosing a drag chain cable.
There are several drag chain cable sizes and failure to choose the right size is disastrous. Still, the drag chain size is not the only thing you need to consider. You also need to consider the cable chain type in accordance with your intended application. The image below shows the type of application suited for each of the two main cable chain types namely, nylon cable drag chain and steel cable drag chain.
Other factors that you need to consider when choosing a cable drag chain include;
The chain&#;s cable clearance
The chain&#;s fill
The chain&#;s cavity setup
The chain&#;s bending radius
Last Updated on May 14, by Richard
How to select a cable carrier: A motion engineer&#;s guide
Selecting the right kind of cable carrier for an application starts with a few simple guidelines. The most important points to consider are the specifics of the application. These include the length of travel, the number of cables or hoses, the size and weight of the cables, the required speed and acceleration and environmental factors such as exposure to any debris, excessive heat or chemicals. Knowing the weight of the cables also ensures that the carrier won&#;t fail by snapping in two.
Cable carrier styles can be either open or closed. Open varieties allow for easy access to the cables and visible access as well, whereas closed carriers seal off the cables from the environment to protect from environmental contaminants such as metal filings.
Environmental conditions play a large part in selecting a cable carrier. If the application is in a dirty or contaminated area, an enclosed carrier is the best choice. An open carrier is lightweight and makes inspecting and replacing cables easier.
One of the most crucial factors is choosing the right bend radius for the cable carrier. Bend radius is measured from the center of the curve loop to the center of the pivot pin on the side link. A larger bend radius means less stress on the cable and a longer service life. It&#;s important for the bend radius, with the exception of applications with space restrictions, to be larger than the recommended minimum bend radius of the cables and media that make up the fill package.
All cable carriers have a predetermined radius stopping point on each link. When a number of links are assembled, these stopping points restrict the carrier from fully pivoting and form a curve loop, or minimum bend radius.
All cable carriers have multiple bending radii to choose from and every manufacturer suggests a minimum bend radius. The bending radius chosen for the cable carrier will depend on the cable or hose with the largest diameter. Selecting a considerably larger bend radius than required for the fill package will extend the lifespan of the cables and hoses.
General rules for selecting the bend radius
Don&#;t exceed the manufacturer&#;s suggested minimum bend radius; however, using the largest bend radius possible is optimal.
If you don&#;t know the recommended minimum bend radius of the cables in the fill package, follow these guidelines from NFPA 79 : &#;Cables with flexible properties subject to movement shall be supported in such a way that there is neither mechanical strain on the connection points nor any sharp flexing. When this is achieved by the use of a loop, it shall provide the cable with a bending radius of at least 10 times the diameter of the cable.&#;
The larger the bend radius, the less stress is put on the cables and hoses, which will ensure longer service life.
Keep in mind that the minimum bending radius is partly based on a temperature range for flexing. Special consideration is needed when the environment reaches or exceeds the temperature rating for the cable. This is especially true for low-temperature applications using thermoplastic cables, which tend to stiffen when exposed to the cold. Stiff cables can raise the radius of the cable carrier and lead to mechanical failures. Best practice is to use a cable with a low-temperature rated PUR or TPE jacket and/or consult the manufacturer for bend radius recommendations.
In applications with severe space restrictions, the bend radius of the cable carrier may need to be smaller than the recommended minimum bend radius for the fill package. This is not ideal, but if it cannot be avoided, use cables specially designed for low bend radius installations or consult your cable carrier manufacturer for the best solution.
Special drag chain cables are designed for applications involving constant movement, bending, and mechanical stress. These cables, often used in industrial automation, robotics, and other dynamic environments, need to be installed correctly to ensure long-term performance and durability. Improper installation can lead to premature cable failure, increasing maintenance costs and downtime. In this article, we'll explore the key installation tips and precautions for special drag chain cables.
1. Understanding the Drag Chain System
Before beginning the installation process, it is essential to understand the drag chain system's design and function. Drag chain cables are engineered to move freely within the chain without twisting, kinking, or tangling. Therefore, selecting the right drag chain and ensuring it matches the cable specifications is crucial. Make sure that the cable has sufficient room within the drag chain to bend and move without excessive tension or compression.
2. Choosing the Right Cable
When selecting a special drag chain cable, consider the environmental conditions and operational requirements. Factors such as temperature, exposure to chemicals, mechanical stress, and the number of bending cycles should be taken into account. High-flex cables designed specifically for drag chain applications offer better resistance to fatigue and wear. Choose cables with suitable insulation and jacket materials for the specific conditions of the application, ensuring they can handle extreme environments if necessary.
3. Correct Cable Length
An important factor in installing drag chain cables is ensuring the correct length of the cable. The cable should have enough slack to accommodate movement within the drag chain without stretching or being overly tight. However, too much slack can cause the cable to loop or twist, leading to increased wear. Generally, it&#;s recommended to allow about 10% extra length to compensate for the movement within the drag chain.
4. Securing the Cable at Both Ends
Properly securing the cable at both ends of the drag chain is essential to prevent unnecessary strain and movement. The cable should be fixed at the stationary end of the drag chain, allowing it to move freely on the side where the movement occurs. Ensure that the cable is clamped or secured gently without excessive pressure that could damage the outer jacket. Additionally, the fixed points should be strong enough to hold the cable in place under mechanical stress.
5. Avoid Twisting or Overlapping
During installation, take care to lay the cables straight and parallel within the drag chain. Twisting or overlapping cables can lead to excessive friction, heat buildup, and increased wear, ultimately resulting in cable failure. To prevent this, ensure that each cable lies in a separate chamber within the drag chain or is properly spaced. For multi-layer installations, use a separator or divider to keep the cables from rubbing against each other.
6. Ensure the Minimum Bending Radius
Each drag chain cable has a specified minimum bending radius, which must be maintained throughout the installation to avoid cable fatigue and damage. Exceeding the bending radius can cause internal conductor breakage, reduced signal transmission, or even complete failure. Make sure that the drag chain is designed to allow for the proper bending radius, and check the manufacturer&#;s guidelines for each cable used.
7. Check the Cable Tension
It&#;s crucial to check the cable tension within the drag chain. The cable should not be under excessive tension, as this can result in pulling or stretching. On the other hand, the cable should not be too loose, as it may sag or cause entanglement. Ideally, the cable should be under slight tension to move smoothly within the drag chain without creating extra stress on the conductors or insulation.
8. Routine Inspection and Maintenance
Even after proper installation, routine inspection and maintenance are necessary to ensure the longevity and reliability of the drag chain cables. Regularly check for signs of wear, abrasion, or damage to the cable&#;s outer jacket. Look for any twisting, tangling, or improper alignment within the drag chain. Timely maintenance can help prevent unexpected failures and costly downtime.
9. Preventing External Damage
In environments where the drag chain cables are exposed to external elements, such as dust, debris, or chemicals, additional protective measures may be needed. Consider using protective conduits or shields to prevent abrasion and corrosion. These protective covers can help extend the cable&#;s lifespan by minimizing exposure to damaging substances. Make sure that the chosen protection is flexible enough to move with the drag chain without hindering its motion.
10. Follow Manufacturer Guidelines
Always follow the manufacturer's guidelines for installing special drag chain cables. Each cable may have unique specifications, including bending radius, temperature range, and chemical resistance, which should be strictly adhered to during installation. Ignoring these specifications could result in poor performance or premature cable failure.
Conclusion
Proper installation of special drag chain cables is essential to ensure optimal performance and long-term durability in dynamic applications. By following best practices such as ensuring the correct cable length, maintaining the minimum bending radius, and avoiding twisting or overlapping, you can significantly extend the cable's life and reduce maintenance costs. Routine inspections and following the manufacturer&#;s recommendations will help keep your drag chain system running smoothly and reliably.
When it comes to choosing high-quality drag chain cables for extreme environments, trust Amissiontech&#;s range of specialized solutions designed for longevity and resilience. Reach out to us to learn more about how our products can support your industrial applications.
At Amissiontech, we are committed to providing cutting-edge solutions for your most demanding applications. Our specialty drag chain cables are designed to meet the highest standards of performance, reliability, and durability. If you have specific requirements or challenges, please contact us to learn how our products can meet your needs.
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