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2.01
B EF' = Total width of cable carrier with glide buttons (K series) or glide shoes (QUANTUM) Bi = Usable inner carrier system cavity width Bk = Outer width of the cable carrier BSt = Stay width when using LG bar frame stay c = Distance between bored holes on LG bar frame stay d = Cable outer diameter D = Bored hole diameter when using LG bar frame stay d R = Roller tube diameter when using RMR frame stay FE = The non-moving, fixed end of a carrier system FP = The fixed point of a carrier system H = Mounting height hG = Outer link height h G' = Outer link height when using glide shoes h i = The inner carrier system cavity height KR = The bend radius of a carrier system L B = The loop length (directly related to the KR) L f = Unsupported cable carrier length L k = The required/calculated carrier system length LS = Total machine travel L V = Fixed point offset from the center point of travel ME = The moving end of a carrier system n Z = Number of comb tines on comb style strain relief qz = Additional load RKR = Reverse bend radius SF = Safety factor S H = Horizontal separator/shelf thickness ST = Vertical divider thickness t = Link pitch tB = Elasticity factor Commonly Used Abbreviations & Symbols
= usable link cavity Bi = inner cavity width Bk = outer link width h i = inner cavity height hG = outer link height
B i
h i hG
Bk Carrier Cavity
V isual G lossary
Horizontal Cavity Shelf / Separator
Glide Shoe (removable)
Frame Stay Bar
Vertical Cavity Divider
Side Band
Symbology You will find these symbols used in this Technical Handbook to bring attention to important Rules of Thumb and Key Formulas.
A Rule of Thumb is a principle which applies in most cases but is not intended to be strictly accurate or reliable for every situation.
= Rule of Thumb
A Key Formula is a standard formula used by KabelSchlepp to calculate critical dimensions and figures that are needed when specifying a cable and hose carrier system for an application.
= Key Formula
Commonly Used Conversions Multiply By To Obtain Millimeters 0.03937 Inches Inches 25.4 Millimeters Kilograms 2.205 Pounds Pounds 0.4536 Kilograms Feet/Second 0.305 Meters/Second Meters/Second 3.28 Feet/Second Kilograms/Meter 0.6720 Pounds/Foot Pounds/Foot 1.488 Kilograms/Meter
∑ = Total sum Ø = Diameter
Specifications are subject to change without notice. KSA-0810-GC
2.02
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Technical Handbook design considerations, tips and helpful information
PACKAGING/SHIPPING
DESIGN
INSTALLATION
MANUFACTURE
In this section:
Pages
DESIGN PROCESS A step-by-step guide toward designing a cable & hose carrier system for your application
STEP 1: Calculate the required cable and hose height ( hi ) and width ( Bi ) clearance requirements for carrier system cavities..........2.04
STEP 2: Select the best carrier type, style and size for your application...........................................................................................2.06
STEP 3: Select the proper carrier system minimum bend radius ( KR ) and applicable drive-arm mounting height ( H ).......................2.08
STEP 4: Summarize and double check your selections. Have you considered everything?...............................................................2.09
STEP 5: Determine the carrier system loop length ( LB ) ....................................................................................................................2.09
STEP 6: Calculate the total carrier system length ( LK ) . ....................................................................................................................2.09
STEP 7: Select mounting bracket style and mounting position........................................................................................................2.10
DESIGN CONSIDERATIONS Use our experience and know-how to your advantage!
SECTION 1: Carrier frame stay system options..........................................................................................................................2.12
SECTION 2: Cable and hose strain-relief systems......................................................................................................................2.13
SECTION 3: Know your cables and their specification details....................................................................................................2.14
SECTION 4: Carrier system placement and operating mode options.........................................................................................2.16
SECTION 5: Material properties of nylon polymer and metallic carrier systems in varying environmental conditions..................2.20
SECTION 6: Support tray and guidance for standard and circular cable and hose carrier system operating modes....................2.25
SECTION 7: Extended travel systems including guide channels, support rollers, rolling carriage systems and more....................2.27
SECTION 8: Things to consider when using high duty-cycle extended travel carrier systems......................................................2.36
SECTION 9: Important points to remember when designing a cable and hose carrier system....................................................2.37
SECTION 10: Proper installation and start-up of cable and hose carrier systems..........................................................................2.39
SECTION 11: Typical causes of cable and hose carrier system failures.........................................................................................2.41
SECTION 12: Proper shipping, transport and storage procedures for cable and hose carrier systems..........................................2.44
SECTION 13: Suggested regular inspection procedures for all carrier systems............................................................................2.45
STEP 8: Placing your order with KabelSchlepp ................................................................................................................................2.46
APPLICATION DATA & QUOTE REQUEST SHEET Let our skilled engineers help you select and order the best system solution for your application .......................................................2.47
Specifications are subject to change without notice. KSA-0810-GC
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2.03
Calculate The Required Cable And Hose Clearance Requirements For The Carrier System Cavity
Step 1
1.) To determine the required carrier system inner cavity height h i , you must:
“X”
b i
cavity area
h i
carrier link cross sectional view
a.) Add the following required clearance Safety Factor ( SF ) around all your cables, pneumatic lines, and/or hydraulic hoses:
Cables → Add 10% to the outside diameter
minimum clearance around the O.D. = "X" must be > 1.0 mm
Pneumatic Lines → Add 15% to the outside diameter minimum clearance around the O.D. = "X" must be > 2.0 mm Hydraulic Hoses → Add 20% to the outside diameter minimum clearance around the O.D. = "X" must be > 3.0 mm
b.) The largest of these cable, air line or fluid hose outer diameter values, with the safety factor added (Ø +SF ), determines the minimum inner cavity height required ( h i ). ■ Make note of the largest c Ø + SF , pn Ø + SF and hyd Ø + SF values in your application and use the largest of these as the minimum required h i value. 2.) To determine the required carrier system inner cavity width ( B i )
cavity area
B i
h i
carrier link cross sectional view
a.) Add up all the aforementioned cables, air lines and fluid hoses plus safety factor values.
∑ c Ø + SF + ∑ pn Ø + SF + ∑ hyd Ø + SF = ∑ ALL Ø
good Weight Distribution
Cavity Fill
not recommended
good
not recommended
Cable/hose weight is unevenly distributed inside the carrier cavity causing unbalanced carrier system operation which could result in system failure
Cable/hose weight is evenly/symmetrically
Cable’s/hose’s outer diameter takes up the entire cavity causing premature wear on the cables/hoses and carrier system
Space in each cavity partition allows for the cable/hose outer diameter plus the recommended safety factor
distributed inside the carrier cavity allowing for balanced carrier system operation
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b.) Use vertical cavity dividers for best overall operating results: to keep unlike components apart to keep unlike cable or hose jacket materials apart when cable or hose outside diameters are less than 60% of the selected or available inner cavity total height (< 60% of h i ) individual flat cables must be kept separated, in a private compartment to prevent cable or hose tangling and damage to aid in maintaining the best left to right symmetrical weight distribution and balance of the carrier cavity contents maximum cavity fill should be less than or equal to 60% of cavity area if and when using horizontal shelving, you must not exceed the max. cavity fill criteria herein stated for each cavity created
good
not recommended
max. cavity fill < 0.6 x cavity area
c.) If in accordance with the aforementioned recommendations for your particular application (step 2b), adding vertical dividers is required, add to the total value of ∑ ALL Ø (step 2a) the total space required for all vertical cavity dividers ( ∑ div ) you deem necessary to best separate cables and hoses from one another (remember not all carrier types have dividers available, choose carefully). c1.) Also determine if dividers should be installed at interval of every link, every 2nd, every 3rd or every 4th link / frame stay throughout the entire carrier system. Every 2nd link is used as our default interval. A maximum divider interval of every ½ meter through the entire length of the carrier is recommended. c2.) If the resulting B i is wider than the space available, stacking certain cables and/or hoses is possible when using horizontal shelving components seen in the KabelSchlepp catalog. All design rules and safety factors still apply. Please consult factory. ■ Make note of the total width ( B i ) value required for your application
Vertical dividers placed every link
Vertical dividers placed every 2nd link
∑ ALL Ø + ∑ div = B i
Vertical dividers placed every 3rd link
Note: The example worksheet below helps identify and calculate the cavity height ( h i ) and width ( B i ) required.
Applicable Cable or Hose Safety Factor Multiplier
Actual Cable or Hose Diameter(s) or Size
Number of Cables or Hoses and Dividers
Cable or Hose Type
Cable or Hose Diameter with Safety Factor
Actual Space Required
Air
1.15 1.10 1.20
1.00” 1.25” 1.50”
1.15” 1.38” 1.80”
4 4 2
4.60” 5.52” 3.60”
Cable
Hydraulic
Largest Height Requirement of Carrier Content
1.80” = hi (Min. Height)
Total from all above =13.72 2.70 Add numbers above 16.42 = B i (Minimum Width)
9
Dividers
.30
Number of Dividers in Cavity
Narrowest Width Requirement
Specifications are subject to change without notice. KSA-0810-GC
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2.05
Select The Best Carrier Type, Style & Size To determine the best carrier system product group and type, select a carrier product group type and style that best suits your application needs, objectives and budget.
Step 2
1.) Basic selection criteria: Application Speed
As application speeds increase, proper carrier system selection becomes critically important. This chart depicts a range of different KS cable carriers’ suitability to the spectrum of application speeds commonly seen in today’s highly automated world.
QUANTUM Fastest > 15 Meters/Sec.
VARITRAK M Faster ≤ 15 Meters/Sec.
Rule of Thumb
UNIFLEX Fast ≤ 10 Meters/Sec.
CONDUFLEX Moderate ≤ 5 Meters/Sec.
Note: This chart is meant to be used as a general rule of thumb. Factors such as acceleration, load weight and orientation also play a major role in determining a carrier type’s suitability to a particu- lar application. Higher speeds than those listed in this chart are often possible. Always consult the factory for assistance with high speed applications.
VARITRAK S Slow ≤ 3 Meters/Sec.
Spectrum of Application Speeds
Slow Speed
Fast Speed
Machine Tool
Automation
Pick & Place
Typical Application Types
2.) Basic selection criteria: Type
3d Multi-axis movement
modular extruded
Mono Molded Plastic
modular plastic / HYBRID
MODULAR steel
MICROTRAK, PLASTITRAK, UNIFLEX Snap together links, moderate speed, extended travels, non- conductive, corrosion resistant, radiation resistant, easy to handle, light weight
VARITRAK K, MC, MK, MT MASTER HC, LC & LT Snap together side bands linked with various cable carrier cavity types, high speed, extended travels, non-conductive, low noise, clean-room rated, corrosion resistant, easy to handle, light weight
QUANTUM Extruded one-piece side bands, highest speeds, clean-room rated, vibration free, quiet, non- conductive, corrosion resistant, multi-axis capable, lightest weight to size ratio PROTUM Extruded, press-in installation.
VARITRAK S Modular construction, longest self-supporting spans, highest strength, heaviest loads CONDUFLEX (not pictured) Tube style, smooth running, stainless steel shell with polymer cavity liner
ROBOTRAX Ideal for non-linear applications that require rotating, twisting, and other complex motions. Modular construction with press-in cavities for easy content installation, light weight, extra rugged
3.) Basic selection criteria: Style
MICROTRAK, PLASTITRAK, UNIFLEX, VARITRAK K, MK & MC, PROFILE, QUANTUM, ROBOTRAX, PROTUM, MASTER HC & LC Debris passes through carrier, light weight, better cavity cooling properties than enclosed tube styles, allows examination of contents
UNIFLEX BT, VARITRAK MT, VARITRAK S RMD, MASTER LT, CONDUFLEX Contents are completely shielded from debris, contents hidden from view, red-hot chip protection, aesthetically pleasing
open carrier
enclosed tube
Specifications are subject to change without notice. KSA-0810-GC
2.06
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Technical Handbook design considerations, tips and helpful information
4.) Basic design selection criteria: Mono or Modular To determine the best cavity frame stay design (Mono or Modular) and size for the carrier type and style selected you must consider the following:
a.) Mono Designs: One or two piece molded links that snap together.
1. Non-Opening Cavity Access: designs require cables or hoses to be fished through center cavity or carrier system. This type of carrier system consists of simple molded links available in a wide range of widths that can be snapped together to easily create customized system lengths.
Mono
2. Opening Cavity Access: design has snap-open bars or lids for cables or hoses to be easily “dropped” into carrier cavity. This type of carrier system consists of simple molded links available in a wide range of widths that can be snapped together to easily create customized system lengths.
The proper carrier family size needs to be selected, once one of the two aforementioned designs has been selected which has a cavity size available that best suits the inner height ( h i ) and width ( B i ) requirements calculated above.
b.) Modular Design: Carrier systems consisting of molded polymer, aluminum, and plated steel with countless design options available through assembled components.
■ Please note the KS system product group (type and style), design (mono or modular) and size.
1. Hinged or Twist Opening Access to Cavities: design has snap-open bars or lids that are hinged as well as twist in and out (90 degrees, with open ended wrench) for cables or hoses to be easily “dropped” into carrier cavity.
Modular
2. Bolted-on/off Bar Access to Cavities : designs have bolted-on (can be easily disassembled by simply unbolting parts) reinforced aluminum bars for incredible strength and design flexibility (size, configuration, etc.)
The proper carrier family size needs to be selected, once one of the two modular aforementioned designs has been selected, which has a cavity size available that best suits the inner height ( hi ) and width ( Bi ) requirements calculated above.
5.) Basic selection criteria: Cavity Size Once the best product type and style has been selected, find the proper cavity size available within that group type and style that best accepts the calculated inner cavity width ( B i ) and height ( h i ) values including all applicable safety factors.
■ Please note the KabelSchlepp system product group, type and style.
Specifications are subject to change without notice. KSA-0810-GC
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2.07
Step 3
Select The Proper Carrier Bend Radius (KR) & Mounting Height (H)
1.) Determining the Bend Radius (KR): To determine the correct carrier system bend radius ( KR ), use the largest cable or hose in your particular application and multiply the most appropriate KabelSchlepp standard bend ( KR ) radius safety factor as listed below:
When possible, using the cable or hose manufacturer’s published specifications. However, when this information is unavailable, consider the following rules of thumb:
for continuous hi-flex-cables use 7.5 x the cable outside diameter as a minimum
for standard continuous flex-cables use 10 x the cable outside diameter as a minimum
for continuous flex-hoses with their contents at less than 1000 psi, use 10 x the hose outside diameter as a minimum
for continuous flex-hoses with their contents at greater than 1000 psi, use 12 x the hose outside diameter as a minimum
2.) Minimum Bend Radius: To determine the minimum bend radius ( KR ) of a carrier system, use and select the closest available bend radius size option (catalog example: Option A, B, or C etc.) that properly accepts the minimum bending requirements calculated (step 3, number 1 above) of the largest cable and/or hose from within the selected carrier product category, design, and size in the KabelSchlepp catalog. a.) If this list of bend radii ( KR ) size options is too small, move to the next larger carrier size within the product group and type you have selected and select the best bend radius option available there.
Abl_0650
b.) Always allow 10% (1.10 multiplier) operating space above the carrier system loop ( H z ) for the inherent “crown” or pre-tension.
cable carrier may have inherent crown/pre-tension ( Hz )
H z = H x 1.10
c.) Make note of the bend radius ( KR ) option that best fits your application requirements.
GENERAL DATA
CL Total Machine Travel (L S )
E CONOMIC V ALUE A DDED 3
Extended
Retracted
Moving End
L B
t = Link Pitch
Increasing Cable/Hose Life When selecting a cable carrier system, always choose a cable carrier that has a minimum bend radius ( KR ) that is equal to or larger than the manufacturer's recommended minimum continuously- flexing bend radius of any of the cables or hoses used in the carrier. Typically, increasing the bend radius of the car- rier system will reduce the amount of bending stress that is put on cables and hoses resulting in longer operational life. Therefore, it is recommended to use the largest cable carrier bend radius option that will still fit within your operating en- velope.
H
A product group’s EVA score is a general indicator that allows a customer to quickly and easily compare a product group’s basic price, features, capabilities and value relative to other comparably sized products within the KS product range. Download 3D CAD files, videos, updated product info & much more at: www.kabelschlepp.com/plastitrak.htm
0320 � 1.26 (32)
KR
Fixed End
L S = total machine travel L B = 3.14 x KR + (2 x t safety factor) L K = chain length required L K = LS ÷ 2 + length of the curve (L B )* * Assumes the Fixed Point is located at the Center of the Total Machine Travel. Calculation of Chain Length
U B
Dimensions in inches (mm) Technical Data
Bend Radius KR
Depot
Loop Length L B 7.13 (181) 8.35
Mounting Height H
Series 0320
U B 3.23 (82) 3.62 (92) 4.80 (122) 5.71 (145)
6
3.90 (99) 4.69 (119) 7.05 (179) 8.86 (225)
1.46 (37) 1.85 (47) 3.03 (77) 3.94 (100)
Option A
Option B
(212) 12.05 (306) 14.92 (379)
Option C
Option D * * KR 100 - special order
Self-Supporting Lengths
Larger KR = Longer Life
lbs ft 3.4 2.7 2.1 1.4 0.7
kg m
5 4 3 2 1
Specifications are subject to change without notice. KSA-0810-GC
2.08
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Technical Handbook design considerations, tips and helpful information
Total Machine Travel ( Ls )
Step 4
Summarize And Double Check
Retracted
Extended
CL
At this step, you should now have selected and noted the: 1. Carrier product group (system type, style and link size) 2. Carrier cavity size (cavity inner height h i and width B i ) 3. Carrier bend radius option (the best KR option of those offered for your application) Once you have double checked your selections, you can then move on to calculate the correct carrier system length L k that your application or machine requires.
L
B
t = Link Pitch
H
KR
U
B
Step 5 Determine The Carrier System Loop Length (LB)
To determine the total chain length needed for your cable carrier system in Step 6, you will first need to calculate the carrier's Loop Length ( LB ). The Loop Length ( LB ) dimensions can typically be found listed in the Technical Data section of each product section in the KabelSchlepp Catalog. To calculate the recommended Loop Length ( LB ) yourself, use the formulas listed in the table to the right.
Calculating Carrier System Loop Length (LB)
Plastic cable carriers: L b = (3.14 x KR) + (2 x t ) Steel cable carriers: L b = (3.14 x KR) + (4 x t ) QUANTUM cable carriers: L b = (3.14 x KR) + (12 x t ) PROFILE, CONDUFLEX cable carriers: L b = (3.14 x KR) + (9 x t )
Step 6
CL Calculate The Total Carrier System Length (Lk) Moving End ( ME )
Fixed Point ( FP ) To determine the most economical length of a KabelSchlepp carrier system, in all horizontal or vertical carrier system operating modes, use one of the first 3 formulas listed below to solve for the required carrier length ( L k ) and number 4 to solve for the number of links ( t ) needed.
Fixed End ( FE ) ME = Moving End of carrier system
FE = Fixed End of carrier system
FP = Fixed Point of carrier system
(Ls / 2) + LB = Lk
1.) FIXED POINT AT CENTER OF TRAVEL For a carrier system that has its fixed point located centrally relative to the total machine travel use:
Fixed Point at Center of Travel
CL
Moving End ( ME ) Moving End ( ME )
CL
Fixed Point ( FP )
L S 2
The total travel ( L S ) divided by 2 + the carrier loop length ( L B as defined in catalog) = The Required Carrier Length ( L k )
Fixed Point ( FP )
+ L B = L k
(Ls / 2) + LB = Lk (Ls / 2) + OFFSET + LB = Lk
Fixed End ( FE )
Fixed End ( FE )
2.) FIXED POINT AT END OF TRAVEL For a carrier system that has its Fixed End located at either the extended or retracted [far] end of total machine travel use:
CL Fixed Point at End of Travel
Moving End ( ME )
CL
Moving End ( ME )
CL
Moving End ( ME )
Fixed Point ( FP )
Fixed Point ( FP )
The total travel ( L S ) + the carrier loop length ( L B as defined in catalog) = The Required Carrier Length ( L k )
Fixed End ( FE ) Fixed Point ( FP )
L S + L B = L k
(Ls / 2) + OFFSET + LB = Lk
Fixed End ( FE )
Ls + LB = Lk
(Ls / 2) + LB = Lk
Fixed End ( FE )
3.) FIXED END OFF CENTER OF TRAVEL For a carrier system that has its fixed point located somewhere not central to, or at either end of the total machine travel use:
CL
Off Center Fixed Point
Moving End ( ME )
CL
Moving End ( ME )
Fixed Point ( FP )
Fixed Point ( FP )
The total travel () + the offset from the center of the machine travel () + the carrier loop length () = The Required Carrier Length ()
L S 2
Fixed End ( FE )
Ls + LB = Lk
+ OFF cmt + L B = L k
Fixed End ( FE )
(Ls / 2) + OFFSET + LB = Lk
Specifications are subject to change without notice. KSA-0810-GC
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2.09
Moving End ( ME )
Step 6
Calculate The Total Carrier System Length (Lk) (continued)
4.) Once the carrier system length ( L k ) is determined, this length must be divided by the selected carrier type link pitch ( t ) to calculate the correct number of links to be used and ordered. Always round up to the nearest link!
(L k ÷ t) = ∑ t
Note: Always remember to divide the required length ( L k ) by the selected KabelSchlepp carrier system pitch ( t ), rounded up to the nearest link, to get the correct ( ∑ t ) total number of links the system requires.
5.) If a system with circular travel action or a multi-axis (movement in the X+Y, X+Z, etc.) travel action is required, please consult the factory with the following information:
a.) for a circular travel system (typically tipped onto its side), please define (see page 2.26): ■ the center fixed point of total travel action ■ the total degrees of rotation ■ start and stop points to the aforementioned rotation ■ the moving end location (rotates along the I.D. or O.D. of the system)
■ the minimum inner operating diameter dimension ■ the maximum outer operating diameter dimension
b.) for a multi-axis travel system , please define: ■ the center fixed point of total travel action ■ total distance and direction of travel, from the fixed point location, in one (example “X”) axis of travel ■ the total distance and direction of travel, from the fixed point location, in another (example “Y”) axis of travel ■ the total distance and direction of travel, from the fixed point location, in another (example “Z”) axis of travel
Step 7 Select Bracket Style And Mounting Position
Finally, always remember to include the correct [product group] carrier system mounting brackets.
a.) Identify one of the following mounting styles and positions desired: i.) Style: Universal, 2 piece, 4 piece, and flange are some of the common options. Availability is dependent upon carrier type and size. Special order custom brackets can also be provided if needed. ii.) Position: Position options vary and will be dependent upon the bracket style selected.
Examples of Common Bracket Types
Standard left and right hand brackets
Universal style brackets without strain relief
Standard bracket with snap-on strain relief
Standard bracket with integral strain relief
Standard bracket without strain relief
Specifications are subject to change without notice. KSA-0810-GC
2.10
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Technical Handbook design considerations, tips and helpful information
Step 7 Select Bracket Style And Mounting Position (continued)
2 Piece Standard Mounting Bracket
Standard 2 Piece Mounting Brackets Commonly used on mono molded link type carrier systems, KabelSchlepp 2 piece mount- ing brackets are commonly offered with or without integral strain relief. In some cases, the optional strain relief piece can be detached from the bracket and mounted separately for ad- ditional installation options. Brackets are made of nylon, hybrid nylon & aluminum, or steel dependent upon size and type of carrier system.
UMB (Universal Mounting Brackets) Because UMB brackets can be attached to the mounting surface from above, below or at the front of the bracket, they allow a great deal of installation options from a single bracket type. Dependent upon size and type of carrier, these brackets are made of reinforced nylon (smaller sizes) or cast aluminum (larger sizes).
4 Piece Standard Mounting Bracket
Standard 4 Piece Mounting Brackets Offered on a wide range of KabelSchlepp carrier systems, 4 piece standard brackets offer a wide range of possible mounting positions. 4 piece brackets are typically made of high strength stamped steel. Specifying Mounting Position Most Kabelschlepp mounting brackets can be installed in multiple different positions dependent upon the application. See each product's individual mounting bracket pages for available options. A sample mounting bracket configuration is shown below:
Bracket End M - Moving End F - Fixed End Bracket Position A - connecting surface on
For 4 pc brackets with positionable feet:
MH
MA (Standard)
A I (Standard)
outside radius (standard)
MI
I - connecting surface on inside radius H - connecting surface turned 90° to the outside radius K - connecting surface turned 90° to the inside radius U - Universal Bracket (not pictured, see opposite page)
MK
FK
I (Standard) A
FI
Bracket feet on the standard 4 pc brackets can be positioned facing inward (I) which is the standard position or facing outward (A)
FA (Standard)
FH
Please specify the desired bracket variant and position when ordering . Example: FAI/MAI (Standard) or FAA/MIA The bracket positions at the Fixed End and Moving End can be changed later if required.
Specifications are subject to change without notice. KSA-0810-GC
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2.11
Carrier Frame Stay System Options
DESIGN CONSIDERATIONS - Section 1
The numerous frame stay configurations explained below offer the designing engineer a wide range of options suitable for almost any application requirement. Custom designed options specifically designed to suit your unique application can be developed by our engineering department. For custom designs or assistance, please contact KabelSchlepp’s technical office: 1-800-443-4216 or www.kabelschlepp.com. Type: MONO
Mono type frame stays are molded at fixed widths and typically come in non-opening and opening versions, dependent upon the size and series of the cable carrier. Systems with a mono type frame stay tend to be less expensive and have less configuration options than comparably sized systems using modular frame stays. Type: RE Standard open style system - installation uses twist in/out bars – selected for its ease to access the carrier system cavity. Can be ordered in 8 mm (smaller sizes) and 16 mm (larger sizes) custom width increments. Smooth fiber reinforced molded polymer bars. Type: RS Standard open style system - installation uses two twist in/out aluminum bars - selected for its ease to access the carrier system cavity. Any custom cavity width can be ordered. Smooth cable/hose friendly extruded light weight aluminum bars. Type: RS 2 Standard open style system - installation uses two bolts per bar - selected for its strength and ease by which the carrier system cavity can be accessed by removing the bolted-in bars. Any custom cavity width can be ordered. Smooth cable/hose friendly extruded light weight aluminum bars. Type: RV Standard open style system - installation uses twist in/out reinforced bars – selected for its added strength and extreme ease to access the carrier system cavity. Can be ordered in any custom cavity width. Smooth cable/hose friendly reinforced extruded aluminum bars. Type: RMS Standard open style system - typical installation uses four bolts per bar – selected for its super-duty strength and rigidity and ideal for extra wide and heavy carrier systems. Carrier system cavity can be easily accessed. Any custom width can be ordered. Smooth and wide cable and hose friendly extruded aluminum bars for superior protection against cable/hose wear. Type: RMR Standard open style system - installation uses four bolts per bar – selected for its strength, rigidity and best-in-industry cable/ hose friendliness. Any width can be ordered. Smooth and durable cable/hose friendly extruded aluminum bars available with free-rolling integral Delrin ® support and dividing systems for ultimate protection against cable/hose wear. Type: RMD/RDD Standard enclosed cavity system - installation uses four bolts (RMD) or snap-on lids (RDD) – expressly designed for applications requiring protection against debris. Available in fiber reinforced molded polymer (RDD) or smooth high strength extruded aluminum materials (RMD). RMD's aluminum lids can be ordered in custom specified widths. MT's nylon lids are available in standard width increments of 8 mm (smaller sizes) or 16 mm (larger sizes). RMD aluminum lids are suitable for protection against red-hot debris. Type: RMA Custom open cavity extender system - installation uses four bolts and twist in/out bars – specifically designed for applications in which large diameter hoses need to be carefully guided. Any custom width can be ordered. Smooth cable/hose friendly extruded aluminum bars and high strength polymer extender bars. This system can only glide on itself when extender bars are attached to the outer radius together with an open bottom style guide channel. Type: LG Custom open hole style system - installation uses four bolts per bar – selected for its super-duty strength, rigidity and precise separation and placement of all cables/hoses on the carrier system's neutral axis (where the cable/hose relative movement is minimized). Cables and hoses can be easily accessed for maintenance. Any custom width, hole size and shape can be ordered. Type: RS 1 Standard open style system - installation uses twist in/out aluminum bars on the outside radius and bolted-in aluminum bars on the inside radius - selected for its ease to access the carrier system cavity. Any custom cavity width can be ordered. Smooth cable/hose friendly extruded light weight aluminum bars.
Specifications are subject to change without notice. KSA-0810-GC
2.12
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Technical Handbook design considerations, tips and helpful information
To dramatically increase cable, hose as well as carrier system performance and longevity, proper cable and hose strain reliefs at both ends of the carrier system are required. KabelSchlepp offers a wide variety of effective cable & hose clamping systems, examples of which are shown below. DESIGN CONSIDERATIONS - Section 2 Cable & Hose Strain Relief Systems
D
B
C
A
A Tie-wrap style - “Comb” style plates
B Saddle style – Screw-down modular clamps C Block style – Screw-down split block clamps
D SZL style – Snap or Screw-down clamps
Specifications are subject to change without notice. KSA-0810-GC
Need help? 1-800-443-4216 or www.kabelschlepp.com
2.13
Know Your Cables & Their Specs
The following information should be used together with other explanations and design recommendations in this Handbook.
Cables that have failed typically show the following symptoms:
■ corkscrewing where cables twist in themselves ■ knotting of conductors underneath the cable jacket ■ cables twist around one another within a cable carrier system ■ cables are sticking out between the cable carrier crossbars and getting caught in the bend radius
■ cables entangled with other cables and crossbars tearing them apart ■ loss of conductivity through simple breaking of cable conductors
An example of corkscrewing where cables twist themselves.
Common causes of cable failure when operating in a cable carrier system:
■ cables used are not designed for use in continuous flexing operation ■ cables are packed too tight inside the cable carrier cavities ■ the actual operating bend radius of the application is smaller than the minimum bend radius recommended by the cable manufacturer ■ cable carrier design is not cable friendly or optimal for the types of cables being used
Cable failure showing entangled cables and ruptured jacket.
Proper Unspooling Of Cables And Hoses
All too often those more commonly selected or used industrial cables are not designed for continuous flexing or bending operation as seen in cable carrier systems. They will quickly cork-screw and knot, especially when run within a tight cable carrier bend radius. Also, many standard industrial cables require a bend radius larger than most machinery applications allow and as a result, force these cables to run at a tighter than recommended radius. This will undoubtedly substantially reduce cable life. A cable specifically designed for continually-flexing tight bending radii must be selected.
Some commonly used cables also use a cotton tape between the inner conductors and the outer jacket. Due to the constant bending when operating within a cable carrier system this cotton tape will often bunch up underneath the jacket and crimp the conductors causing premature cable failure.
Cables with a built-in twist will develop a cork-screw effect more easily. Additionally, this inherent twist is further amplified by the constant flexing and relative-movement of the cable operating in a cable carrier until the cable conductors break. The best choice for a cable to be used in a cable carrier should be PVC/PUR/TPE/TPM jacketed. Cable jackets made of rubber or neoprene are generally not recommended. The latter two materials are too sticky and do not allow the cables to move easily relative to one another and the cable carrier. This will also contribute to the aforementioned cable knotting.
When installing cables or hoses into a carrier system, they should be laid into the carrier without twist and in accordance to the guidelines outlined in this Technical Handbook. Cables or hoses should not be simply pulled off the top of a reel. Instead, they should be properly uncoiled from a reel as shown in the illustration above.
Specifications are subject to change without notice. KSA-0810-GC
14
2.14
A member of the TSUBAKI GROUP
Technical Handbook design considerations, tips and helpful information
Cables designed for use in continuous motion applications using cable carrier must be manufactured on a unique cabling machine that will minimize any back-twist on the cable core.
Continuous Flex – In such cases the cable is rolling back and forth in a linear motion resulting in the cable (and conductors within) to flex in an equivalent way. This is typically the case for all cables that are approved for use within cable carrier systems where required bend radii are typically 10x the cable O.D. or less.
Torsional Flex – In such cases, the cable is being twisted clockwise and counterclockwise off its center-line axis with angles varying from 90 to 360 degrees “rotation”. This type of flexing typically occurs on multi-axis robotic machinery that requires constant twisting and flexing over a sustained period of time.
Bending Flex – In such cases, the cable is flexing back and forth off a stationary point. Industry commonly refers to this as a tick-tock motion. A vast majority of the stress on the cable in such a case are the two focal points where the bend and load are being applied.
GENERAL APPLICATION RANGE OF FLEXIBLE CABLES
FIELD INSTALLATION
LIMP CABLE
CASUAL FLEX
CONTINUOUS HI-FLEX*
Building
Extension Cords
Power Cords
Gantry Robots
Coaxial
Welding Cable
Pick & Place Machinery
Communication
Stage Lighting
Automated Machinery
Instrumentation
Sound Cable
Machine Tools
* Cables that are considered to be continuous hi-flex are typically the best choice for use in dynamic cable carrier systems.
Understanding Cabling Techniques
Unilay or Bunch – In such cables conductors (copper groups or bunches of wire strands) of any number are twisted together with the same lay direction and cable lay length. Bunch construction will not have a well defined geometric configuration and may have a variable cross-section. A Unilay construction will have a well defined geometric configuration and a defined cross-section. This type of cabling technique is usually used in static applications and designs.
Concentric Contra-Helical – In such cables conductors are surrounded by well defined layers of helically laid conductors. Each layer has a reversed lay direction and an increasing lay length in each succeeding layer. This type of cabling technique is usually used on continuous flex cable applications and designs (that should be used in cable carriers).
Concentric Unilay – In such cases conductors are surrounded by one or more layers of helically laid conductors with the same direction or lay and increasing lay length in each succeeding layer. This type of cabling technique is usually used in torsional flex applications and designs.
Specifications are subject to change without notice. KSA-0810-GC
Need help? 1-800-443-4216 or www.kabelschlepp.com
2.15
Common Carrier Operating Modes
DESIGN CONSIDERATIONS - Section 4
The following carrier system orientation photos show some of the most common ways that cable and hose carriers are applied in the real world. Contact the KabelSchlepp factory for assistance if your application requires an orientation not shown.
Horizontal "self-supporting"
Horizontal "with permissible sag"
Horizontal Supported "w/ support rollers or tray"
Horizontal "gliding in guide channel"
Specifications are subject to change without notice. KSA-0810-GC
16
2.16
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Technical Handbook design considerations, tips and helpful information
Horizontal Long Travel "using KabelSkate"
Horizontal Long Travel "w/ rolling carriage system"
Side Mount
Rotary
Specifications are subject to change without notice. KSA-0810-GC
Need help? 1-800-443-4216 or www.kabelschlepp.com
2.17
17
(continued)
Circular " with reverse bend radius in guide channel"
Vertical - Standing "loop on top"
Vertical - Hanging "loop on bottom"
3 Dimensional "multi-axis movement"
Specifications are subject to change without notice. KSA-0810-GC
2.18
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Technical Handbook design considerations, tips and helpful information
Two Axis "vertical and horizontal"
"multiple chain system"
Nested "multiple chain system"
"multiple chain system"
Specifications are subject to change without notice. KSA-0810-GC
Need help? 1-800-443-4216 or www.kabelschlepp.com
2.19
DESIGN CONSIDERATIONS - Section 5 Material Properties
Properties Of Nylon Cable Carrier Systems In Different Environmental Conditions
KS has materials suitable for harsh or extreme indoor as well as outdoor applications. Standard Polymer Operating Temperature Range: -40° F (-40° C) to 266° F (130° C)
Environment
It is recommended to use our special hot or cold temperature materials or our steel chain systems, when sustained operating temperatures remain below -13° F (-25° C) or above 185° F (85° C). Once either of these levels is eclipsed, the mechanical values are reduced and service life degraded. Please consult KabelSchlepp for a suitable solution. Chemical, flame, debris, UV and temperature resistant materials are readily available whenever required.
Nylon cable carriers can also be used in vacuums. In the case of intermittent loads the traction forces occurring should be ascertained. Please consult our factory in every such case.
Vacuum
With a dose of up to 1 megarad the material does not deteriorate. When the dose is increased to 100 megarads the material becomes steadily more brittle. The maximum limits of the mechanical properties drop by 30% at 100 megarad. Where the dose exceeds 100 megarad . the use of nylon cable carriers is not recommended. Please consult our factory in these cases. According to the testing process in line with VDE 0304 Part 3 (05.70) the standard material (KS-PA, reinforced with glass fiber) corresponds to classification II c. Tested in line with UL 94 - ASTM 0635-81 Classification: “UL 94-HB” Tested in line with DIN 4102, “Burning characteristics of construction materials and component parts” Classification: Construction material class B2, minimum thickness < 1 mm, not dropping if burning.
Resistance to Radiation
Flammability
For plastic cable carriers able to withstand cold storage areas, a special material is used. These cable carriers can only be produced in yellowish/ white (transparent).
Resistant to cold storage
Cable carriers for use in areas at risk of explosion or static discharge resistant, are produced from a special material and are only available in black. Since there is nothing to differentiate them by sight from standard cable carriers, these cable carriers are identified with a stamp marked “ EX ”. ■ Flash point of special material: 536° F (280° C)
Ex-protected cable carriers
■ Ignition temperature of special material: 779° F (415° C) ■ Surface resistance: <10 5 Ω (Standard Material min. 10 10 Ω) ■ Volume resistance: <10 5 Ω x cm (Standard Material min. 10 12 Ω x cm)
Specifications are subject to change without notice. KSA-0810-GC
2.20
A member of the TSUBAKI GROUP
Technical Handbook design considerations, tips and helpful information
Properties Of Steel Cable Carrier Systems In Different Environmental Conditions
Cable carrier systems may be applied in the following temperature ranges dependent on the frame stay option selected.
Temperature
Frame Stay Variant Frame stays with nylon parts Bolted aluminum frame stays
Temperature Range - 40º F (- 40º C) to 266º F (130 ºC) -13º F (- 25º C) to 482º F (250 ºC) - 40º F (- 40º C) to 752º F(400 ºC)
Bolted bar stays (complete steel system)
Note: Take care in using a suitable cable or hose. Note: Please also consider the allowable temperature ranges for cable installations.
KabelSchlepp cable carrier systems with side-bands made of steel are resistant to a wide variety of chemical influences.
Chemical Resistance
Note: Please note that cable carriers made of galvanized steel are not acid resistant. For applications in an aggressive environment, we recommend rust and acid resistant stainless steel cable carriers.
To protect your cables and hoses against dust and particulates or other mechanical influences, we offer you our cable carrier systems with stainless steel chip covers or easily serviceable aluminum lids. ■ Stainless steel chip covers - contact factory ■ Frame stays with aluminum lids - frame stay variant RMD
Dust and Particulates
Steel cable carrier systems are protected against corrosion and may be applied in humid rooms or in outdoor environments. Stainless steels for green sea environments and the food industry are also available. The nylon material used in some frame stays is UV resistant!
Humidity & UV Influences
Electrostatic Discharge Protection
Cable carrier systems with steel chains are conductive and have an electrostatic discharge. Thus, they are suitable in explosion-hazardous environments.
Note: Steel cable carriers must be grounded at the mounting brackets.
Specifications are subject to change without notice. KSA-0810-GC
Need help? 1-800-443-4216 or www.kabelschlepp.com
2.21
Nylon Polymer Material Specifications & Details
Standard Color: Black is the standard color. Molded plastic cable and hose carriers can be supplied in other colors. Standard Material: 35% Glass fiber reinforced Nylon 6 resin.
Molded plastic cable and hose carriers can be supplied in other colors including red, green, blue, yellow, orange and many more. Please remember to always provide correct PMS color code(s) for special color(s). — Special Order Only! Molded plastic cable and hose carriers for application in the range of radioactive radiation or for permanent temperatures below –40° F (40° C) require special additives and can also be supplied by KabelSchlepp. The plastic used is free of halogens, silicon and heavy metals such as lead and cadmium. No formaldehydes are used in the manufacturing process. Plastic components meet food industry standards and can be used without restriction. Please give us detailed information on your environment conditions. All nylon chains are also available in flame retardant materials of various colors. — Special Order!
Admissible Operating Temperatures Standard Operation: –40°F (–40° C) to 266° F (130° C) for short term operation: 392° F (200° C) Chain side bands reinforced for high strength, stiffness, straightness, and performance at elevated temperatures.
UNITS
REINFORCED NYLON 6
TEST METHOD
TEST
ENGLISH
(METRIC)
ENGLISH
(METRIC)
Key mechanical properties Tensile strength at yield
PSI
(MPa)
D-638 D-368 D-790 D-790 D-256 D-648 D-785
28,500
(197)
Ultimate elongation Flexural strength Flexural modulus
%
3
PSI PSI
(MPa) (MPa) (J/m)
40,500
(279)
1,500,000
(8,966)
Notched izod impact strength Heat deflection temp. @ 264 PSI Rockwell hardness (M scale)
ft. lbs. /inch
3.4 419 104
(183) (215)
°F
(°C)
Shrinkage (1/8" bar)
in./in.
0015
General physical properties Specific gravity
D-792 D-789
1.41 428
Melting point
°F % %
(°C)
(220)
Equilibrium moisture content @ 50% RH
2.0 6.2
Saturation moisture
in.
1.0 x 10 -5
(1.8 x 10 -5 )
(mm)
°C
Coefficient of linear thermal expansion
°F
D-696
(mm)
in.
3.6 x 10 -5
(6.5 x 10 -5 )
Flammability (1/16" bar)
UL-94
94 HB
Chemical resistivity of the standard KabelSchlepp nylon material. (The data listed below was developed in actual laboratory tests (factory certified). Please contact us for all materials not shown in this table.) Against Resistance Against Resistance Against
Resistance
Acetic Acid
■
Formaldehyde and Polymac.
●
Oleic Acid
●
●
Formic Acid
●
Paint & Lacquers
●
Acetone
■
Greases and Waxes
●
Paraffin, Paraffin Oil
●
Ammonia
● ● ● ● ● ■
Hydraulic Oils
● ■ ●
Polyester Resins
● ● ● ● ● ● ■ ● ● ●
Benzine, Benzole
Hydrochloric Acid (aqueous)
Potassium Hydroxide
Bitumen
Lactic Acid (aqueous)
Potassium Chloride (aqueous)
Boric Acid (aqueous)
Lactic Acid
▲ Potassium Nitrate (aqueous)
Butyric Acid
Liquid petrol gas. (DIN 51622)
● ● ● ● ● ● ●
Propane Gas, Propyl. Hydride Sodium Carbonate (aqueous)
Calcium Chloride (aqueous) Chlorine, Chlorinated Water
Lubricants, Edible Fats
▲ Mercury
Tartaric Acid
Chromic Acid (aqueous)
● ● ● ●
Methyl Acetate
Tartaric Acid (aqueous)
Diesel Oil
Milk
Vaseline
Ethanol
Mineral Oil
Xylene
Ethyl Acetate
Oil - Edible and Lubricating
Fluorinated Hydrocarbons
● = Resistant
■ = Conditionally Resistant
▲ = Not Resistant
Specifications are subject to change without notice. KSA-0810-GC
2.22
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