Flexible Cable Manufacturers India
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All About Flexible Cable Manufacturers India

As our power requirements have become extremely specialized, cables are now also required to provide for these specific requirements. Flexible cables were specifically designed where we were dealing with moving objects, often requiring the cable to move along. Also known as ‘continuous-flex' cables, these cables had to be bunched or looped together. This meant that the cable can be bent easily and with tight radii.

This is not to be confused with flex or flexing cable, which is designed to accommodate for the flex life cycles for as long as required. Flexible cable manufacturers, on the other hand, design their cable for easy flexibility and not for flexing motion. In simple words, flexible cables are those that can bend easily.

The demand originally came from the automation field. It was observed that when moved, cables often failed inside their cable carriers, even though the carriers stayed intact. This meant that fault was with the cables. Sometimes, the cables would have serious damage, which brought the whole production line to a grinding stop. This led to the demand for cables with higher flexibility.

Applications Given their high flexibility and durability, flexible cables find a really wide range of applications. Some of these are:

- Drag chain applications
- Machine tools
- Data processing equipment
- Robotics
- Production assembly lines
- Automation
- Computing hardware industry

Type of Cable Flexing
The applications of flexible cables are not just to be looped up in a circle. It has a wide usage across a range of industries today. Accordingly, there are four types of flexing movements that we see frequently. These are:

Rolling flex: This type of flexing motion is seen most commonly in linear motion, such as in cable track system. For instance, we see rolling flex in rolling motion carrier where cables are kept enclosed in the carrier.

Bending flex: Here cables have to go through repeated motion at a fixed point. The stress comes from a lateral motion.

Torsional flex: This kind of flexibility is required when a cable faces twisting motion, usually a circular motion around its axis.

Variable flex: This is a miscellaneous category which includes different types of motions that cables are subjected to. It could be a combination of the above or some other movement.

There are broadly two types of flexible cables. Each is explained below:
Cables with stranded conductors laid in layers: Here the core are long and stranded. These are laid in layers around the centre. The stranded conductors are then encircled by a extruded tubular jacket. In shielded cables, the conductors are enclosed in foils or fleece. For flexible cable manufacturers, this is an easy process. It is also cheaper than the alternative. On the flip side, the compression and stretching of the inner and outer radius varies as the cables is flexed, bended and twisted. Overtime, this causes material fatigue with the core now taking on its own shape — its zones of stretching and compression — which ultimately leads to damage.

Cables with braided or bundled conductor: Here the problem of the tension around the centre is solved by adopting a braided layout and removing the multi-layer design. By removing the layers, we have a uniform radius for all the bending conductors. At the flexing point, there is no segregation of conductors facing increased or decreased bend, which means that there is no distortion. The jacketing of the cable ensures that the conductors maintain their twisting position.

Unlike the extruded jacket of stranded cables, here we have a pressure filled jacket. This further ensures that the conductors stay in their position while in motion. This type is usually stiffer and more expensive. However, it has a longer life. The flexibility of the cables is achieved through copper conductors. Because of its high conductivity, very thin copper wires can be used for conductors. This, in turn, allows us to construct flexible constructions.

Continuous flexible cable
This types of cable is not just flexible, it must also have the ability to withstand twisting, bending and moving with the appliance. We often see this in robotics where a cable has to continuously bear different types of flexible movements.

With the increasing presence of automations and robotics in productions, flexible cables manufacturers today have an increasingly important role to play. As processing technology improves, we have been able to design and achieve more and more flexibility.

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