WHITE PAPER:

How cable selection can significantly reduce

lifecycle costs
Checklist helps in making complex purchasing decisions

November 2019
 Summary

Many cables are similar in
structure and have identical
electrical properties.
(Source: igus®)
Function units for transmitting energy to machines require a large number of electrical cables. In
addition to the classic control cable, a distinction is made between data cable, BUS cable, servo
cable, etc. Usually sold by the metre, many cables have a similar structure and identical electrical
properties. This is often interpreted as a leeway for decision-making and does not remain without
consequences. In the rarest cases, supposedly cost-effective cables meet the requirements of
complex machines. This leads to downtime and high repair costs - with correspondingly negative
effects on the Total Cost of Ownership and Life Cycle Costing (LCC). In order to avoid that and
also significantly reduce the cost, the checklist presented here can help decision makers. The list
presents the key factors for cable selection and illustrates the relevance of the parameters for all
decision makers.

Wrong decisions will lead to additional costs in maintenance.

A Deloitte study "Purchasing as a value driver in mechanical and plant engineering" states that procurement
management plays a key role in cost-cutting measures and efficiency enhancements. Purchasing in mechanical
and plant engineering is often responsible for 50% of the costs. From this it can be concluded that purchasing
is the biggest EBIT lever. Simply put, if savings are made in purchase and the requirement for efficiency is
fulfilled, operating profits increase.

(Source: Adobe Stock Photo, macrovector)

An extract from the findings of the study "Supply Chain Management in Industrial Enterprises" states for
example, "[...] that in 74% of the companies surveyed, the part price is a decisive selection criterion for
suppliers". About 100 decision makers from purchase and logistics departments of industrial companies with
over 500 employees participated in the study of the commissioned consulting firm. The problem: unplanned
additional costs for transport and control are often incurred especially by suppliers with extremely cost-
effective parts prices, for example from Asia. Furthermore, a high personnel effort may be observed in the
logistics department, with supply and quality problems. The crux of the matter is that supposed savings in
purchase appear elsewhere as additional costs, but associations are then no longer apparent in the system
and so obviously there is no room for improvement. Non-technical decisions and the motivation of mechanical
engineers - to stand up to competition from the Far East through improvements at the product and process
level - stand in the way.

Valuable components guarantee product durability

How can this dilemma be solved and how can the right quality be identified as a cost advantage? Which
facts are essential to make the right decision for a specific component and to positively influence the product
life? By definition, "technical product life" refers to the time span between the marketing/delivery of plant and
its final failure. However, this can have many causes, such as poor quality or performance of materials and
components. In technical terms this is called material obsolescence.
Conversely, the choice of higher quality components, appropriate to the application, leads to an extension of
the technical service life. For capital equipment such as machine tools, prolonging the technical service life of
the product is particularly important, as it is associated with considerable resources.
1
https://www.maschinenmarkt.vogel.de/sparen-im-einkauf-verursacht-erhebliche-mehrkosten-a-864291/
A high service life of the product can be achieved in plant
construction through expenditure in R&D and product
development. Added value can be generated when procurement
of quality and therefore durability of components, is placed
above efficiency enhancement.

High availability of cables and hoses is particularly

important for machine tools.
(Source: igus®)

More than two billion test strokes and about 1,561 production monitoring tests are conducted every year at the igus® laboratory, Cologne.
(Source: igus®)

Worst case: save €34 and generate a loss of €148,000!

If an increase in efficiency has too high a focus, this can have consequences, as the example of a fully
automated warehouse for long products at the Cologne-based company igus® demonstrates. The motion
plastics specialist had recently ordered a warehouse for long products and clearly stipulated the cable to be
installed (from their own company) in the specifications to the supplier. The smooth commissioning took place
after the delivery, which provided as usual no matching between specified and actually installed components;
the "wrong" Ethernet cable slipped through the net during the initial installation. Almost a year later, during
production operation, the total failure of the long goods warehouse occurred unexpectedly. The cause was
that the installed Ethernet cable in the energy chain was broken. It was only then found that the cable was not
the one which had been ordered.
The total cost difference between the ordered system with an Ethernet cable from our own company and the
one actually delivered amounted to only €34. These costs, which are negligible in accounting terms and in the
overall context of the investment price, are now offset by additional costs of €148,000. The reason was that
products of this financial volume could not leave the warehouse. Expenses such as for the troubleshooting
or repair personnel are not included in this sum, just as the damage to reputation caused by delivery delays
cannot be quantified.
This case illustrates how efficiency-oriented action actively prevents improvements at the product and process
levels - for the price of €34.

No contradiction: cleverly budgeted and yet innovative

Scenarios like these can be avoided if companies take the same care in selecting the cables as they do with
mechanical components that are also crucial to the functionality of plant. This saves maintenance costs and
indirectly ensures a longer service life, as the following example illustrates:
A manufacturer of fully automated gates and doors requires new cables designed for operation in an energy
² 1 Prakash, S .; Dehoust, G .; Gsell, M .; Schleicher, T. and Stamminger, R. (2016): Influence of the operational life of products on their
environmental impact: creation of an information base and development of strategies against "obsolescence".
chain. The electrical specifications are: 4-core cable with a cross-section of 0.5mm. Cables like these adhere
to the standard of German cable manufacturers and are also available from igus®, listed in the catalogue under
the product name CF 888. Among the available cables is the classic version with PVC outer jacket, which is
recommended for indoor use. The energy chain specifies the bend radius of 12.5xd. According to laboratory
tests, these parameters can guarantee 5 million cycles. The list price for this cable is €0.42.
The same cable with four cores and 0.5mm cross-section is also available with an outer jacket made of TPE
and has little difference in feel and appearance. The bend radius of this option is much smaller with 4xd. The
manufacturer estimates a service life of 40 million cycles based on its own laboratory results and long-term tests.
At €24.50, this version with TPE jacket is more expensive.

The decision for the optimal cable does not strictly depend on the specification by the engineers; €0.42
compared to €24.50 is a strong incentive to install the cost-effective cable: superficially, it has an identical
electrical performance and apparently it can perform even less because of the lower bend radius. Although
the cable with the TPE jacket guarantees 40 million cycles, the 8 times more cycles do not justify an almost
57 times higher price from an economic point of view.
The dilemma is decided, because a consideration of the jacket with different insulation materials and various
conductor materials is not taken in the context of service life and the fully automated use of a door and its
(permanent) stresses.
This is because lift doors in a four-storey residential building with 8 parties
are subject to completely different loads than for instance the frequently used
entrance doors of an emergency room. This means that questions about the
application site, climate and frequency of use must be taken into account
when selecting the cable. If these parameters are neglected, in the long run
Questions about application site,
minimal cost savings are offset by expenses due to downtime, maintenance
climate and frequency of use
and last but not least, costs for avoiding the loss of reputation. must be taken into account when
selecting the cable
(Source: igus®)

More safety for decision makers: service life calculation

Engineers know that every cable has its purpose - no application is the same as another. A large number of
manufacturers therefore offers a wide variety of cables. This includes the motion plastics specialist igus®, which
has a total of 7 options of the aforementioned 4-core cables with a 0.5mm cross-section in its portfolio. The
special feature: the company does not just sell by the metre, but offers safety and more product service life -
through a combination of electrical and mechanical specifications combined with various types of stranding,
stranded wires and jacket materials. Using the service life calculation, customers can look through all the
options online. The basis for the service life calculation is valid data from a test laboratory.
Here the chainflex cables - igus' proprietary brand - are specifically tested for moving applications in energy
chains or for robot applications for maximum service life in realistic test facilities. The data gained is used to
further develop products and service life calculators so that customers can configure their preferred cable. The
test laboratory is unique in the German industry and covers more than 3,800m². In the large labs, an average
of 800 tests on chainflex cables are conducted in parallel.
That adds up to more than two billion test strokes per year.
In addition, approximately 1,561 production monitoring
tests are conducted annually, resulting in over 292 million
double strokes. This is made possible by, among others,
63 test installations, where just under 1.4 million electrical
measurements are also carried out every year. In terms of
cables, the company checks all the assumable parameters
with the aid of a climate chamber, via external tests, using
a noise chamber and a travel of more than 200m, or (Source: igus®)

additionally installed robotic systems. The data from all test series - now available for more than 20 years -
is continuously being incorporated into the development of an online service life calculator for cables. An
absolutely unique feature of igus® cables is the guarantee for 36 months or alternatively of ten million cycles
for the chainflex cable. The goal: maximum cost savings over the entire service life.

Four tips for the decision maker

Answers to the following questions are relevant for companies to find the cable that gives them the best
transmission characteristics with the highest cost savings:

1) What stress is to be expected on site?

2) Which type of movement is required here?
a. What speeds and accelerations are expected?
b. How does travel or torsion take place?
3) What are the temperatures the application is exposed to?
4) What are the (chemical) influences on the applications and cables?

Detailed answers ensure that a cable - whether for BUS, measuring systems, motors, servo drives or control
systems - is designed/intended precisely for the specific application. This ensures an optimal cost-benefit ratio
over the entire product life cycle of a machine.

For practical use from real-life findings.

The work with the checklist is illustrated using the example of the fully automated long goods warehouse
described at the start:
The first question, "What is the expected stress at the site of application?" can be clarified by decision
makers and technicians via the system and requirement specifications and the design. The Ethernet cable to
be integrated into the long goods warehouse will transmit data in a state of permanent motion. The Ethernet
cable is installed in linear guides and energy chains. These components named energy chains are available
in various models and designs on the market and are available as e-chains® from igus®. Regardless of brand
and model, they guide and protect cables of all kinds; even pneumatic and hydraulic.
The second question, "Which type of movement is required here? What speeds and accelerations are
expected? How does travel or torsion take place?" Most of these topics can be answered by specifying
the application. How the energy chain should be dimensioned is usually defined by the design. In most cases,
the fixed end connection of an energy chain is placed in the middle of the travel. This results in the shortest
connection between the fixed and moving end and, at the same time, the most economical chain length. From
this, the cable length can be calculated.
Which bend radius is relevant for the operation of a cable, depends on the energy chain used. For the bend
radius - the extent to which a cable can be bent without damaging it - the following applies: the smaller the
radius, the more specific the entire cable structure must be in terms of strand structure, stranding type and
selected insulation and jacket materials. Important reference points as to how much different cables can be bent
generally without damaging them can be found in the industry standards such as IEEE 1185, ICEA S-75-381,
ICEA S-66-524 or ICEA S-68-516. As a rule of thumb for operation in energy chains, the chain radius must
be greater than the recommended minimum bend radius of a cable. It is generally recommended not to
exceed the minimum radius specified by the manufacturer. Cables with flexible specifications, should also be
supported so that the connection points are not mechanically stressed and sharp bends are avoided. Also
important for the right decision: as the load on a cable decreases, its service life is automatically extended. In
addition, the minimum bend radius is always to be seen in the context of the ambient temperature. The cable
withstands the stresses only if the operating temperature recommended for that cable is not exceeded.
The energy chain is the limiting link in terms of speed and acceleration. Simply put, every specific energy
chain needs "its" cable. This becomes clear, when there are
rotary movements on a machine. Now, twistable additional loads
must be taken into account in the cable selection. For example,
in applications with spiral-shaped energy chains, it is not
uncommon for cables to withstand thousands of circular
movements during their lifetime, in which they rotate several
times around their own axis. In order to achieve process reliability
and full functionality over the entire service life of the product, all
of these aspects should be taken into account when deciding on
a cable.
In order to define the right jacket material, the
question of the prevailing temperatures of the
application is also important.
(Source: igus®)

The variety of cables is not only reflected in their electrical specifications, but also in a wide variety of jacket
materials. In order to define the right jacket material, questions 3 and 4 are relevant. What are the "prevailing
temperatures" of an application? Is the cable subject to "chemical influences" or is there any exposure to
oils in the process?
A look at industry-specific production conditions and communication with the design department will provide
the reference points. Not every pharmaceutical production plant needs cables and jacket materials suitable
for cleanrooms, and swarf does not arise in every manufacturing industry.
The widely held opinion that PVC for the jacket is suitable only for applications with low stress, while PUR is
the optimum for every energy chain, falls short.

An examination of the following environmental parameters and potential correlations is recommended:

• Mechanical load
• Temperature
• Possible exposure of the cable to chemicals
• Possible contact with oils, for example, as lubrication, hydraulic fluid, thermal oil or shaft oil
• Required approvals, certificates and standards (UL, CC, etc.) for operation and/or export.
In the example of the long goods warehouse, the mechanical load on the Ethernet cable is the critical point.
 Diagram left: contact with oils, as lubricant, hydraulic fluid, thermal oil or shaft oil affect the life of cables. Diagram
right: the correct approvals and certificates for cables are important for the export and future viability of German
mechanical and plant engineering.
(Source: igus®)

Jacket materials: a science in itself

In order to make the best choice for the jacket material, focusing on the following reference points may be helpful.
Cables made of PVC are less expensive, suitable for low to medium stress and for operation in the chain for
ambient temperatures of + 5°C to + 70°C. Today, in the range of cables, PVC covers a wide variety of complex
applications. igus® has further developed the PVC material and its specifications. In the low voltage range (up
to 1000 V) PVC is still known as the material with the best price/performance ratio. Due to the very abrasion-
resistant material mixture, PVC is ideal for use in an energy chain. But there are now PVC jackets available in
oil-resistant as well as non-oil-resistant blends on the market. The elastomer is considered as a plastic with
thermoplastic properties for versatile use. Due to its chemical structure and low flammability, PVC is used on
production and assembly lines. PVC cables are extremely strong and show excellent specifications even with
thin wall thicknesses. The material is resistant to permanent moisture and salt water. The jacket material is also
highly resistant to abrasion and bending, but less notch-resistant. Polyvinyl chloride can release halogens and
hydrogen cyanide in case of fire, which are dangerous for humans.

Example of various minimum bend radii depending on the jacket material (Source: igus®)

The PUR jacket material is ideal for use on machine tools, because it is one of the notch-resistant materials
and offers high oil-resistance. When used in a chain, PUR can withstand an extended temperature range of
-25°C to +80°C and is also highly UV-resistant. PUR coats are thermoplastic, halogen-free and can be flame-
retardant. In its consistency, PUR resembles rubber up to a certain temperature and has high flexural fatigue
strength. Added to this are limited cold flexibility and very good chemical compatibility with other materials.
Cables with a PUR jacket are resistant to oil and coolant and can be free from toxic halogens. PUR jackets are
characterised by notch resistance, but also have relatively high abrasion values.
The mix of all specifications makes cables with PUR jackets the ideal solutions, when, for instance in
plant construction, the lack of abrasion resistance is compensated by the contact with lubricating oils.
Compared to this, PUR materials show a very high abrasion behaviour when used "dry" in an energy chain.
TPE jackets are recommended where the specification requires the highest UV resistance and highest flexural
strength and the cable is exposed to oil or organic oil. Use in a temperature range of -35°C to 100°C is possible
for TPE, if the cable is installed in an energy chain. Whenever a machine or system needs to operate in a highly
dynamic manner, TPE offers itself as a thermoplastic elastomer because it can withstand mechanical stresses
and is very resistant against external influences such as chemicals or temperatures. TPE has good notch
resistance and the best abrasion properties of the materials mentioned here. In addition, the jacket material is
halogen-free, but could be made flame-retardant with an admixture of halogen substances and is compliant
with UL 94-HB. TPE is ideal for permanent motion in energy chains and is therefore often found in cables in
crane applications, in conveyor technology or in applications in the low temperature range.
CHAINFLEX®

CHAINFLEX®

CHAINFLEX®

CHAINFLEX®

CHAINFLEX®

CHAINFLEX®

CHAINFLEX®

CHAINFLEX®
The aspect of the right jacket material requires much more attention.
(Source: igus®)

Conclusion

The example of the long goods warehouse makes it clear that by using the checklist and questioning the
complexity (how dynamic is the application?), much more weight would have been given to the aspect of the
right jacket material than was obviously the case. The choice would have been either TPE or a cable with PVC
designed specifically for these high requirements - just what igus® had specified. That would have only cost €34
more, but prevented damage amounting to €148,000.
If lifecycle-based models such as Total Cost of Ownership (TCO) and Life Cycle Costing (LCC) must really
work, the decision makers must oversee the stipulated specifications of supplier components accurately and
with no room for interpretation, and follow the technicians' recommendations. For the cables, the checklist
presented here, in combination with the online service life calculator, offers ideal conditions for this. The entire
product lifetime can be planned, resulting in a significant cost reduction over the entire life cycle.

Contact

Rainer Rössel
Phone: +49 2203 9649-278
e-mail: rroessel@igus.net

www.igus.eu/cf-price-check