3 Ways to Avoid Corkscrewed Cables

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3 Ways to Avoid Corkscrewed Cables

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There is a big difference between cables made specifically for continuous-flexing applications and regular flexible cables.

Understanding the distinction is extremely important when you're choosing cables for use inside a cable carrier - or for any automated environment.

Corkscrewed cable

A competitor's corkscrewed cable in comparison with a chainflex® continuous flex cable

If you've ever seen corkscrew damage on a cable, you've probably also asked yourself, “How the heck did that happen?”

It's important to understand the factors behind these kinds of failures and what characteristics a cable should have to prevent this corkscrew effect in the first place.

Check out these three design attributes which will ensure you avoid cables corkscrewing in your continuously flexing application:

Layered cable design

The majority of flexible cables are constructed in layers, but these can corkscrew in demanding applications.

1. Bundle Design

The majority of flexible cables are constructed in layers. While this type of cable is inexpensive to produce, tensile forces pulling the conductors in the outer radius and compressing conductors within the inner radius cause the cable to begin to corkscrew.

Bundled cable design

chainflex® continuous flex cables have a bundled design, which prevents corkscrewing.

chainflex® continuous flex cables are constructed in bundles with short pitch lengths. This design provides inner stability because the tensile forces operating inside balance one another out. The cable will not corkscrew even under maximum bending stress.

Cable with inexpensive filler

The core of the flexible cable is comprised of inexpensive filler.

2. Cable Core

The cable core of a regular flexible cable is comprised of inexpensive filler, which does not protect the stranded structure or prevent the conductors from falling into the center.

Cable with rope like core

chainflex® continuous-flex cables have a tough, rope-like core.

In comparison, properly designed continuous-flex cables have a tension-proof, rope-like center element. This is extremely strong and prevents the type of damage that can lead to corkscrewing.

cable jacket

The jacket of this flexible cable can be pulled off using your bare hands.

3. Cable Jacket

To the naked eye, the jacket of a flexing cable may look the same as that of a cable designed for continuous flexing. However, this cable will not last because its conductors are twisted in layers. As seen in the photograph, the jacket can be pulled off the cable's conductors using your bare hands.

secure cable jacket

The jacket of the chainflex® continuous-flex cable has a high-pressure extruded, gusset-filled outer jacket that cannot be pulled off.

The chainflex® continuous-flex cables on the other hand have a high-pressure extruded, gusset-filled outer jacket, which is resistant to abrasion, oils and chemicals. While the jacket construction allows it to be flexible, you can see from the photo that it is virtually impossible to remove the jacket from the body of the cable.

Useful links

TechTalk Design Advice Series: overview

Download the PDF version of this TechTalk installment.

Application Assistance

For further questions or product information, please contact:

Don Nester

Chainflex® Product Manager

+1 800 521 2747

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