Bend It Like Banner: HighFlex20 Cables Last Longer

Banner Engineering has introduced the HighFlex20 cable series, designed to meet the challenges of moving automation equipment. Built with proprietary HighFlex20 technology, the cables withstand up to 20 million flex cycles, dramatically reducing downtime from cable failures. Available with M8 and M12 connectors, straight or angled options, and lengths up to 15 meters, the PVC-jacketed cables resist oils, abrasions, and chemicals. HighFlex20 cables provide durable, versatile connectivity for gantry systems, tooling, and automated production cells.

A collection of the HighFlex20 Cable series. Image used courtesy of Banner Engineering

Cable Runs In Automated Equipment

Sensors are often placed on tooling that moves around an automated cell, whether an automated assembly or testing cell. Whenever you have a cable that bends, twists, or flexes, you must ensure you use high-flex cables. Banner has recently released a series of cables with M8 and M12 connectors.

HighFlex20 Cable with flying leads. Image used courtesy of Banner Engineering

HighFlex20 Technology

Banner’s new line of high-flex cables utilizes its proprietary HighFlex20 technology. This technology allows the cable to be bent up to 20 million cycles. A cable that can withstand this many cycles can greatly reduce downtime from broken wires.

The cable jacket is made of PVC, which will resist oils, chemicals, and abrasions; other cables would break down if subjected to these substances. The cables can be ordered as double-ended or single-ended with either male or female connectors. Cable lengths range from 1m to 15 m, and there are options for flying lead ends. The connectors are straight or right-angle and come in M12 or M8 standard size; only four-pin connectors and four-conductor cables are offered. Like most Banner products, there are many different options to suit the needs of your application.

A Tabletop cutting machine that utilizes a cable track with high-flex cables. Image used courtesy of Unsplash

High-Flex Applications

A common use for high-flex cables is with servo gantry systems. These systems use servo motors to drive a gripper or end effector on an X, Z, and sometimes a Y axis. The end effector will typically have some kind of feedback, often reed switches for a pneumatic gripper. A high-flex cable will need to be used in the cable track to transmit the end effector feedback to the control system. If the cable breaks, it must be pulled out of the cable track and replaced with a new one. Depending on the size of the gantry, this operation can take hours. By using a cable with Banner’s HighFlex20 Technology, equipment builders and maintenance staff can greatly reduce the chance of replacing a broken cable in a cable track.