Flexible Power Cable

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Low and High Voltage Flexible Power Cable

Znergy’s flexible power cables are designed to be bent and routed in extremely tight spaces without the insulation wrinkling or breaking, and they help satisfy the most demanding application requirements.

Wire insulation that is both high-temperature and high-performance has become a vital feature in today’s platforms. Znergy’s innovative flexible power cables offer a wide range of benefits, including reduced contact stress and reduced mating and de-mating pressures typically associated with circular connections with large shell diameters.

The flexible power cables great flexibility allows it to be bent and routed in extremely tight spaces without wrinkling or cracking of the insulation. As a result, shorter distances may be covered, contact stress is reduced, and mating and demating forces are reduced, which are generally associated with circular connections with high shell diameters.

Flexible Power Cable

Features of Flexible Power Cable

  • Small bend radius and high flexibility allow for intricate routing.
  • Mechanically robust extruded polymer notch and abrasion resistant
  • In engine compartments, vibration stability contributes to a lengthy life cycle.
  • Znergy’s flexible power cables resists a wide range of harsh fluids and offers exceptional low temperature flexibility, making it ideal for compartments exposed to hot diesel fuels and vibration. Lightweight aluminum conductor that saves up to 40% on weight. Copper conductors that are flexible make it easier to route through confined places.

Power cables for Industrial Use

These power cables, which are available in single and multi-conductor configurations, must be able to handle high mechanical loads, speeds, and accelerations. Machine tools, cranes, conveyors, portable designs, and stationary heavy-duty equipment are all common applications. These cables can provide temporary ac or dc power to motors and generators, and depending on their temperature rating, they can be used both indoors and outdoors.

The right cable for an application is determined by its function and surroundings. Use an unshielded cable, for example, only when it will be used in an enclosed environment only accessible by skilled professionals. Enclosures like these reduce electromagnetic interference and keep workers safe from potentially dangerous electrical charges.

Low Voltage Cables are often made with aluminum or copper conductors, insulation, and jacketing. Finely stranded bare copper wires to bunched strands of tinned annealed copper can all be used as conductors. They’re available in shielded and unshielded varieties, and they’re normally required to be flame retardant and grease resistant.

Inside power cables, conductors are either stranded in layers, bundled, or braided. The stranded design is less expensive to produce since it is easier to make. Long, layered cores and stiff strands are encased in an extruded jacket. The conductors are braided around a tension-proof center in the bundled or braided configuration. A uniform bend radius is provided by removing the layers.

Industrial power cables must have tight bending radii, ranging from 5 to 15 times the entire cable diameter, to accommodate the complex and sometimes restricted areas in which they work. To achieve these bending radii requirements, jacketing is also required. As a result, flexible materials like PVC, TPE, and CPE are used to help these cables bend and flex while also protecting them from environmental damage.

Because industrial power cables’ materials, shielding, and jacketing differ, so do their installation processes. Cables can be installed in the following ways by installers:

• Into fixed duct, shafts, and conduit

• Bury cables directly in the ground or even submerge them in water in open-air applications

Znergy Cables are certified and registered cables which ensure that the cables meet essential machine criteria, such as stopping the spread of flames, meeting the application’s maximum voltage demand, enduring severe temperatures, and maintaining integrity even when exposed to oil.

Flexible power cables for communication

Flexible cables, also known as continuous-flex cables, are cables that are designed to withstand the tight bending radii and physical stress of motion control applications. To set them from traditional designs, these incredibly flexible cables were created with distinctive features. These cables are also known as chain-compatible, high-flex, or continuous-flex cables.

A cable’s service life is extended when it has a higher amount of flexibility inside a cable carrier. A normal cable can typically handle 50,000 cycles, whereas a flexible cable can handle one to three million.

There are two types of flexible cables: those with stranded conductors inside the cable and those with bundled or braided conductors.

Stranding in layers is less expensive because it is easier to make. The cable cores are stranded tightly in multiple layers around the center and then encased in an extruded tube-shaped jacket. The cores of shielded cables are usually coated in fleece or foil.

This style of construction, on the other hand, means that as the cable core moves, the inner radius compresses and the outer radius stretches throughout the bending process. Because the material’s elasticity is still sufficient, this can operate well, but material fatigue can set in and produce irreversible deformations. When the cores move, they create their own compressing and stretching zones, which might result in a “corkscrew” shape and, eventually, core rupture. Instead of layering conductors, the other construction method includes braiding them around a tension-proof hub. The absence of multi-layers ensures a consistent bend radius across all conductors.

Every core’s path moves swiftly from the inside to the outside of the cable at any point where the cable flexes. As a result, no single core compresses or strains at the inside or outside of the bend, resulting in lower total stresses. To keep the cores from untwisting, an outer jacket is still required.A pressure-filled jacket fills all of the gussets surrounding the cores, preventing them from untwisting. The flexible cable that results is frequently stiffer than conventional cable, but it lasts longer in applications where it must constantly stretch.

A few basic characteristics are used to choose the proper flexible cable for an application. Determine the application type first. Is the cable going to be stationary or moving? If the latter, is the motion primarily flexing or does it include torsional motion? Is there a need for both flexing and torsion in the application? Different applications have cables that are specifically designed for them.

Znergy’s Flexible power cables are ideal for systems that require large currents and flexibility, such as armored vehicles, tanks, radar systems, public transportation, automobiles, wind turbines, robotics, and ships. Flexible power cables are produced with extremely flexible conductors insulated with Special Compounds (ASC), halogen-free, or FEP materials for extreme conditions.

Advantages of znergy flexible power cables

  • High flexibility for routing in space reduced environments.
  • Easy installation.
  • High current carrying capacity (example: 330 Amps for a 50 mm² at 30°C).
  • High and low temperature resistance.
  • Excellent abrasion and cut-through resistance.
  • Resistant to engine fluids including hydraulic liquid, mineral oil, gasoline and diesel.
  • Operating voltage: 600 VAC , 1000 VAC, depending on the construction. Higher voltage ratings on request.

Application of znergy flexible power cables

Armoured vehicles: power distribution, hybrid electric drives, auxiliary power and control systems, engine management.

  • Tanks.
  • Remote weapon systems.
  • Radar systems: high power radars, airborne radars.
  • Mast systems.
  • Public transport: tramways, metro
  • Cars: electric drives.
  • Renewable energy including wind power.
  • Robots.

With prosperous industry practice, znergy cables are known to offer Flexible Power Cable. It is made by experts using the advanced technology. We strive to produce the most advanced range of products with increased tensile strength, robust insulating resistance, good flexibility, and dielectric strength, with the help of our dedicated employees. We are able to satisfy the market’s expanding needs thanks to our operational competence.

Flexible Wires and Cables are available in a variety of sizes. These are PVC-insulated and made of high-quality copper, resulting in significant energy savings. Our product in this category has a high dielectric strength and resistance to insulation.

Our domain expertise has allowed us to create a fantastic Flexible Cable selection. The given flexible cable is designed and manufactured under the supervision of our expertise utilizing high-quality raw materials obtained from reliable vendors. Furthermore, before final delivery, our flexible cable is rigorously checked by quality analyzers on a variety of criteria to ensure a longer service life and resistance to fire and water.