Flexible high-performance cabling systems pass the toughest tests

chainflex®Developed for flexible applications
chainflex®-cables from igus® were developed from the ground up for use in moving energy chain systems and have proven themselves in a wide range of applications. Among others, the Cat. 6A-cable CFBUS.050 with TPE-outer jacket, in which the cable elements are stranded with a particularly short pitch length, was tested. The precise, very tightly braided overall shield and four pair shields provide reliable and durable protection against external electrical interference. chainflex®The bus cable with PVC and PURjacket were also tested.

Connectors with special wire contacting
The RJ45 modular connectors of the MFP8 series from Telegärtner are characterised by innovative and particularly reliable wire contacting. The individual cores of a cable are pierced during harnessing. The special piercing technology guarantees a particularly stable connection with outstanding transmission values. The connector can be assembled in the field and can be installed on site without special tools, even in tight spaces. The cores are reliably fixed in the specially dimensioned chambers without any gaps, ensuring a stable, force-fit connection with optimum signal transmission.

The innovative "Insulation Piercing Contact" (IPC) technology used by Telegärtner for wire diameters that a standard RJ45 crimp connector cannot accommodate has not only proven itself in industrial applications, but also ensures permanently reliable contacting in telecommunication cable networks and in high-quality IT patch cables. With IPC technology, the fine wires of a stranded conductor are not simply clamped between two insulation displacement connectors (IDC) as with conventional technologies, but are penetrated in a defined manner at three spatially offset points. This pioneering technology offers outstanding, long-term stable contacting and additional safety under tensile loads that cannot always be avoided in practice.

Comprehensive testing far beyond the trade show status of the standard
For the tests, igus® and Telegärtner agreed on a clearly defined division of tasks. The igus®laboratory specialises in load tests under mechanical movement in real applications. Up to 700 tests run continuously in parallel on an area of 2,750 m². The Telegärtner laboratory is one of the technologically leading measuring and testing laboratories for high-frequency measurements on connectors and preassembled cabling. The centrepiece is the real-time re-embedded measurement set-up developed by Telegärtner, which records the relevant parameters not one after the other but simultaneously in real time and is much more accurate than required by the international IEC 60512 series of standards for measurement technology. Telegärtner measurement adapters are therefore often used by leading independent measurement laboratories.

Both companies pioneered the testing of highly flexible industrial cabling. The current version of the EN 60352 standard only defines measurement specifications for cables with solid, single-wire conductors and flexible, seven-wire stranded wire. There are no measurement specifications for the cables with 19-wire, highly flexible stranded conductors required in automation technology. The trend-setting combination of such category 6 and 6A stranded wire and innovative connectors with IPC technology is a pioneering technology that is ahead of the standardisation status of the trade show.