Igus® Servo Cables: What’s New in Flexibility and Reliability Servo cables are put to the test in modern automation and motion systems. They need to endure harsh bending, extreme speeds, twisting, and other environmental stress. That’s why igus® chainflex® servo cables have been designed and made to withstand these challenges with exceptional flex, toughness, and dependability.
● Engineered for Extreme Motion Transmitting power and feedback signals from frequency converters to the motors during dynamic movement is done by servo cables. With these greatly stressful cycles in mind, igus® brands its chainflex® servo flexible motion cables range for precisely that purpose. They also have tough overall shields for intense electromagnetic exposure, as well as extra pair shields for sensors and brakes. This ensures clear and uninterrupted signals even at ultra-fast PWM-controlled drives, making it perfect for high-speed drives.
● Optimized Jacket Materials The right selection of components strays far beyond just picking the right material. At igus®, jackets are made out of PVC, PUR, TPE, or premium materials like hose designed for high oil and abrasive environments. While inexpensive and abrasion-resistant, PVC works only in dry environments. On the other hand, PUR is great where oil is present, while TPE blends work wonders in low temperatures (–35 °C), plus offer good flexibility, superb abrasion resistance, and strikingly high temperatures (+90 °C), making them ideal for cranes, ports, and other heavy industries.
● Enhanced Shielding Construction An outstanding invention is igus®’ internal-jacket design between cores and shield braid. Lab comparisons indicate that cables with this inner jacket preserve roundness and structural integrity over 5 million flex cycles, while simpler fleece-fillet designs suffer from corkscrew deformation after only 145,000 cycles. The outcome: significantly longer service life in high-dynamic conditions.
● Comprehensive Testing & Validation igus® performs extensive in-house examinations for its chainflex® cables, including more than 800 simultaneous flex tests on 64 test stations spanning 4,000 m², resulting in billions of cycles. Many cables are backed by an industry-leading 4-year warranty, supported by UL certification. This kind of information and confidence about performance helps designers make reliable, risk-free decisions regarding cables.
● Custom Cable Classes for Exact Application Cable classes are determined based on four parameters: load capacity, travel length, oil resistance, and torsion. Classes range from basic to top-tier: cables rated as top-tier 6.5.3.1 or 7.x.x.x have extreme bend
radius capabilities reaching 4× the cable’s diameter, long unsupported travel, high-speed operation over 10 m/s, aggressive oil exposure, and up to ±360°/m torsion. These specifications allow users to surpass theoretical limitations and match cables to actual mechanical loads.
Practical Applications Verification By Case Studies Igus® energy chain cables are verified by real-world case studies. ● Operating with high dynamics, machine tools and gantries use CF270.UL.D or CF897 with inner jackets for tight-radius axes. ● Automation for pick-and-place operations requires 400 million strokes. Failure is not an option for chainflex® cables. ● TPE-jacketed motor cables of 600/1000 V for Arctic or tropical use have been proven to withstand extreme environments. ● Over a million double-strokes with torsion? Cat 6A bus cables maintaining 10 GB/s data integrity prove that it is possible to keep performance and data integrity.
New Enhanced Product Assortments Igus® has developed new tools for improved efficiency alongside its outstanding cables: ● CASE cables come in portable stackable boxes with QR-coded labels, which enable 60% faster reorder throughput while cutting shipping costs by more than 80% and improving on-site deployment efficiency. ● Estimating life expectancy accurately modeling with exact industrial cable technology application conditions is done with service-life calculation tools. ● Pre-tested cable-and-chain configurations come in ready-to-use bundles with readycable® and readychain® systems for enhanced reliability while saving time.
Final Thoughts: Movement You Can Rely On igus® chainflex® servo cables redefine flexible motion connectivity. Every design element, from advanced shielding and internal jackets to mission-critical materials and guaranteed certifications, focuses on flexibility and reliability. What this means for engineers is streamlined installations, longer service intervals, and significant decreases in unplanned downtime. To know more, contact Igus® now.
