What are bend radius and minimum bend radius?

The bend radius is the minimum radius a cable can be bent without causing damage. Smaller radii require more flexible materials. The allowable bend radius varies by cable type and is defined by industry standards like IEEE 1185 and various ICEA standards. 
When choosing cables and cable carriers, consider the minimum bend radius. The minimum bend radius is the smallest radius at which an object can be bent without damage. When using cable carriers in installations, it’s important to determine the appropriate bend radius for both the cable and the carrier.
chainflex® cables are designed for dynamic applications requiring small bend radii, making them ideal for tight installation spaces. These cables are engineered to handle high mechanical stress and maintain operational reliability even in the most confined environments. The bend radius of chainflex® cables is typically expressed as a multiple of the cable’s outer diameter, ensuring flexibility and durability. It uses bend-resistant stranded wire and highly abrasion-resistant  jacket materials to enhance cable flexibility. Their extensive testing ensures long service life and reliability for chainflex® cables with small bend radii.

 

How do we select the bend radius of a cable or a cable carrier?

When selecting a cable management system, choosing the correct bend radius for the cable carrier is crucial for extending cable life and ensuring reliability. The bend radius should generally exceed the recommended minimum bend radius of the cables, except in space-constrained situations. Manufacturers offer various bend radii, and the choice depends on the cable with the largest diameter.

General rules and recommendations for selecting the radius 

Ensure you do not go below the manufacturer’s recommended minimum bend radius, but aim for the maximum radius for optimal performance. Cables that move and have flexible specifications need support to prevent mechanical stress at connection points and avoid sharp bends. If using a loop, the bend radius should be at least 10 times the cable’s diameter. A larger radius reduces stress on the cables, extending their service life. Note that the minimum bend radius is influenced by the temperature range for bending, so extra care is needed when ambient temperatures approach or exceed this range.

 In cryogenic applications, thermoplastic cables can stiffen in the cold, potentially causing mechanical errors. Using cables with PUR or TPE jackets is recommended for low temperatures. For space-constrained applications, if the cable carrier radius must be smaller than the recommended minimum bend radius, use cables designed for low bend radius installations. The igus chainflex range offers durable cables suitable for demanding environments.

Where are cables with a tight bend radius used?

The areas of application for cables with tight bend radii are diverse. They are particularly needed in applications where flexible and dynamic movements must be carried out in the smallest possible installation space. For example, they are used in the semiconductor and assembly industry, the automation industry, as well as in the automotive and banking sectors. New application possibilities arise in automatic doors for vehicles and trains as well as in automatic self-service food vending machines and the packaging industry.

Bend radii for cables under 4xd

For users of very small energy supply chains with mostly very narrow bend radii, the question for a suitable cable for very high stroke numbers has come up frequently in the past. At bend radii of less than 5xd, copper quickly reaches its physical limits, which necessitated the search for suitable substitute conductor materials or for fundamentally different conductor superstructures. Alloys are used here. Although they have excellent mechanical specifications, but compared to copper have a reduced conductivity. The conductor diameter of the alloyed conductor is thus a little larger.