We TEST.
Simulating real-life conditions for testing cables is crucial to ensure their reliability and performance in various scenarios. Here's an example of a simulation test for cables, specifically focusing on electrical cables
Test Objective: Evaluate the electrical performance and durability of the cables under realistic conditions.
- Environmental Chamber: Place the cables in an environmental chamber that allows for control over temperature and humidity. Mimic extreme conditions that the cables might encounter during their lifespan, such as high temperatures, low temperatures, and humidity variations.
- Vibration Testing: Subject the cables to vibrations to simulate the conditions they might face during transportation or in dynamic environments. Use a vibration testing apparatus with varying frequencies and amplitudes.
- Bending and Flexing Test: Rigorously bend and flex the cables to simulate installation and usage conditions. Use an automated bending apparatus to apply controlled stress on the cables and assess their flexibility and resistance to bending fatigue.
- Tensile Strength Test: Evaluate the cables' tensile strength by subjecting them to a controlled pulling force. Measure the force required to cause failure, ensuring the cables can withstand the tension they might experience during installation or under load.
- Abrasion Testing: Simulate abrasive conditions by rubbing the cables against rough surfaces. Assess the cables' resistance to wear and tear, ensuring they can withstand abrasion commonly encountered in real-world installations.
- Electrical Performance Testing: Conduct electrical tests under normal and extreme conditions, including high and low temperatures. Measure parameters such as resistance, capacitance, and insulation resistance to ensure the cables maintain their electrical properties across a range of environments.
- Chemical Exposure Test: Expose the cables to common chemicals they might encounter in industrial or residential settings. Evaluate the cables' resistance to chemicals to ensure they remain functional and safe in diverse environments.
- The cables should maintain their electrical properties within specified tolerances.
- There should be no visible damage or degradation after exposure to environmental stresses.
- The cables should withstand bending, flexing, and tensile forces without failure.
- Resistance to vibration and abrasion should meet or exceed industry standards.
- Chemical exposure should not result in significant deterioration or compromise of cable integrity.
Endurance Test
Cable's life-cycle is simulated using drag-chains with different running lengths at different speed and accelleration.
| Run | Accelleration | Speed |
|---|---|---|
| 2 m | 6 G | 600 m/min |
| 5 m | 4 G | 400 m/min |
| 15 m | 2 G | 200 m/min |
| 110 m | 0.5 G | 100 m/min |
Single / Bunch Torsion Test
The cable, or bundle of cables, is rotated according to the imposed angle tothe right and to the left while undergoing a downward pulling force (F). Each alternating motion is considered a cycle.
| Diameter Ranges | Rotation Angle | Test Length |
|---|---|---|
| 5 - 50 mm | ± 540° | 1000 mm |
| 5 - 50 mm | ± 360° | 300 mm |
Alternate Bending Test
The cable specimen to be tested is moved at different speeds and accellerations (sometimes abruptly) to simulate tension, torsion and bending. Part of the cable is attached to a weight, the rest is guided over two pulleys. Each run is considered a cycle.
| Running Lenght | Accelleration | Speed |
|---|---|---|
| 5 m | 4 G | 400 m/min |
Tick / Tock Test
The type of test requires the cable to be subkected to a bending regime (each of which is considered a cycle) based on different load parameters.
The maxium tensile load is 3000N. The maximum cable diameter is 50 mm. The test is comparable to the analogue DIN VDE 0281 Part 2.
| Diameter Ranges | Rotation Angle | Test Length |
|---|---|---|
| 5 - 50 mm | ± 540° | 1000 mm |
