Bergen unveils the essential four considerations for perfect cable assemblies

Cable assemblies are a Bergen specialty.

With more than 80 years of experience in the cable field, Bergen Cable provides an unsurpassed variety of valuable advice to its client base. All one has to do is call up the supplier’s website for a source of expert resources and tips for businesses about cable systems – from the basics to wire-rope specifications. One section of this website involves putting cable assemblies together. It lists the four most important considerations: assembly tolerances, conduit-length tolerances, safety issues regarding breaking strength, and the relationship between cable diameter and pulley or sheave diameter.

Reasonable breaking-strength safety factor

Manufacturing processes often rely on the overall length tolerances that cable systems need, plus the cable’s cut lengths; this directly affects the costs of putting cable assemblies together. Close assembly tolerances are usually more costly regarding production and quality control. Customers should ask the Bergen crew to review and approve permissible tolerance and inspection methods prior to production.

The distance between designated measuring points, as shown in the different sections when specifying assembly lengths, should also be considered. These measuring points are typically located at the fittings’ load-bearing points. Commercial tolerance should equal plus or minus two per cent of the length for an assembly length of at least 100 feet, according to Bergen, and special tolerance should be plus or minus one per cent of the length. These tolerance figures decrease as the lengths decrease.

Bergen personnel should be contacted to review acceptable conduit-length tolerances and inspection methods before production commences. Overall tolerance must be plus or minus ¼ of an inch for conduit lengths from one to two feet – or 0.062 of an inch for lengths shorter than a foot.

Another vital factor to consider is direct stress and the shock in bending loads when determining the cable’s working load. The customer should apply a reasonable breaking-strength safety factor to the load. The standard safety factor is five-to-one in many cases. Finally, users should identify the smallest possible ratios of the tread and cable diameters systems, as pulleys that have been properly designed can boost cable fatigue life.

To learn more, contact Bergen.

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