Four things to consider when putting Bergen cable systems together

Graphic on cable assemblies from Bergen's website.

Bergen Cable offers a wealth of exemplary advice to customers when it comes to cable systems, based on nearly eight decades of accumulated experience in the industry. The company’s website is a goldmine for valuable tips and resources for customers on cable solutions, ranging from basic information to wire-rope specifications.

The site includes a section about putting cable assemblies together, including the four most important considerations: assembly tolerances, conduit-length tolerances, safety factors in breaking strength, and the relationship between cable diameter and pulley or sheave diameter.

Tolerance affects cost directly

Production processes frequently depend upon the overall length tolerances that cable systems require, as well as the cable’s cut lengths. When putting cable assemblies together, this affects costs directly. Close assembly tolerances are typically more expensive in terms of production and quality assurance. Customers should ask the Bergen team to review and approve allowable tolerance and inspection methods before production begins.

The user should consider the distance between designated measuring points as shown in the different sections when specifying assembly lengths. Typically, these measuring points are 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 100 feet or more, and special tolerance should be plus or minus one per cent of the length. These tolerance figures decrease as the lengths do.

In addition, the Bergen crew should review acceptable conduit-length tolerances and inspection methods ahead of production. 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 one foot.

Another important criterion to consider is direct stress and the shock in bending loads when finding the cable’s working load. Here, the user should apply a reasonable breaking-strength safety factor to the load. In many scenarios, the standard safety factor is five to one. Finally, pulleys that are designed properly can increase cable fatigue life, so the smallest possible ratios of the tread and cable diameters should be identified in cable systems.

To learn more, contact Bergen.

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