Sources for High Flex Wire

Why "wire"?

Open the cover of a desktop printer. What connects the travelling part to the fixed part looks like a ribbon with conductors embedded in it. Is this the sort of thing that would do the job?

This one is for all purposes over. The ribbon is the best answer.

Just an opinion.

Mike

Yes that was one of the suggestions was to go to a ribbon wire type of solution. However my existing harness is built using about 13 individual 20-24 guage wires.

So would be easier to update it if they exist.

ECUDesigner

PW has a good suggestion. If you installed the ribbon connectors to the moving and stationary pieces by soldering the hardwires to them. If any problem occured in the wiring it would be a matter of minutes to replace with a new ribbon and be back in operation.

Hi Charsley99,

That is a good idea. I will take a look at it.

Thanks,

ECUDesigner

Find a source for Beldon or Carol cable. Pick a cable that has 4-6 wires that should give you what you need. How are you supporting your current wire?

Mike

I'll have a look here in inventory. We use some hi-flex wire (128 strand) from Germany. Should be able to get manufacturer's details for you tomorrow.

In regards to supporting it, I am using wire ties at various location. It is near these locations where I am getting the most breakage. Also the wire harness get dragged across a piece of plastic so I am protecting that area with a black heat shrink jacket and nylon spiral jacket.

How far is the slide required to travel? I have an extendable boom on one truck, and the manufacturer uses a channel to protect the wiring harness (30 wires 10 to 18 gauge).Try to visualize a bicycle chain being three inches wide. Remove the three inch wide pins and replace each one with two short pins on either side. Now join the side plates to each other with a three inch wide strap on the bottom. This now provides a three inch wide "c" channel to guide the wires in. Because the wires are in a fabric loom they can only move with the channel's movement. This limits the bending of the wire to a smaller angle preventing breaking. I will try to find photos.

I think this is what you're referring to...

How you figured that out from my description is beyond me. That is exactly what I have in the truck. Mine has been in use since 1998. No failures yet. But it does not have to extend (stretch the wires) every day.

Hi Bob,

Like I said, I work with machines that uses this stuff everyday so....

Some of the machines work 24/7 (and move very fast back and forth) and these tracks keep both the electrical and air hoses from getting damaged. The trick is all the lines need to be layed parallel to each other; they should never be twisted or criss-cross.

Hi Rick,

Yes you are right. That is what i am looking for regarding solving my problem. I have also found a vendor lappusa.com and they have a nice assortment of wire for robotic applications so they might have something that will work too.

Thanks,

ECUDesigner

You're welcome.

Most of the machines I work on have that type of track for the motion parts (XYZ platforms). They're often referred to as "scorpion tails".

Good luck.

Any wire designated as "rope lay" will work. Its all in how the wire is twisted into a bundle to allow for flexibillity.

We were buying from Europe, but now the supplier is

TYCAB Australia.

What we are getting is "rope lay", 129 strand by 0.05mm diameter per strand in 1000m spools.

Their address is 269 Frankston Rd, Dandenong, Vic. Australia. Zip/postcode 3175.

You will find them on the net and I'm prety sure they have representation in USA and Europe.

Regarding "scorpion tails" or "caterpillar tracks". They are fantastic at spreading the strain in any moving harness.

The wires fail due to a combination of fatigue and work hardening. By controlling the worst bend radius the wires encounter you can then maximize the life of the wires. Wherever they are constrained (by cable ties or similar) will concentrate the stress into a local bending point and that is why they fail "close to" your tie points.

Hope this helps

<and the wire that I am using is failing>

Instead of the wire -- you will do a lot better using a braided flat-- Copper/SS/Beryllium Bronze.

Google for these

Hi ECUDesigner,

If you can't find any of the flexible wireway mentioned by others earlier at a local supply house, try McMaster-Carr. They are a large and reputable source:

www.mcmaster.com

Type in "flexible cable carrier" in the product search at the left of the site page.

Here also is a closer supplier of flexible wire that may suit your needs:

http://www.daburn.com/2671.html

Hope this helps a little.

PS. I grew up in Daytona and St Augustine. Good to see a fellow Floridian here

Pick up a Ham Radio magazine like CQ or QST. They will have advertisements for antenna wire and coaxial cable. You want to look for antenna wire with a name like flexweave. It will be woven from 100-200 or more fine wires. The idea is that the wire should be flexible enough that any antenna made from it will not break due to flexing in the wind. Maybe even doing a google of flexweave or antenna wire might get you to an appropriate website. try www.radioworks.com they have a wire called Flexweave that is #14 and consists of 168 strands. They want $0.22 US per foot.

Hi Everyone,

Thanks for all the great suggestions. I ended up going with some wire from the Lappusa that is made for flex applications up to 8 million cycles. Their website is http://www.lappusa.com. For our application, I used their Motion Type CF-01 but they had wire for worst flexing than this. The PN that I am evaluating is their PNs 892214 and 892414.

Best regards,

ECUDesigner

Standard coiled phone cords are nearly industructable, I replaced thermocouple wires on a press that cycled 30" 20 times/min, the only failures were from mechanical destruction some have been in use over 10yrs. cheap & easy to change.

Hi Garthh,

I really never thought about using the phone wire. That may be a potential solution too. I need a least 12-14 conductors for my application.

Thanks,

ECUDesigner

It might get a little messy with 3 or 4 cords, you can get outlet covers with swing-over locks & various configurations of outlets. Real easy to change or switch whenever there was a question, the gold plated contacts are nice. We had test leads with the modular ends for troubleshooting the rest of the wiring & controllers. if you cut 1 apart you'll see ribbon wire wrapped around poly string. the coiled configuration spreads out the stress(es),

Hi Snygolf,

I did check Mcmaster car and yes they do have a great assortment. I am originally from Indiana but love it here in Daytona Beach. I do live in Palm Coast which is right in the middle of Daytona Beach and St. Augustine.

The PN from Mcmaster carr that would most likely work is 9936K42. I have ordered lots of mechanical parts from there but not a whole lot of wire.

Thanks for the tip,

ECUDesigner