It’s peak season at your distribution centre in Singapore, and the main palletiser goes down. The error code points to the robotic arm. The cause isn’t a motor or a sensor, but a low-cost drag-chain cable that couldn’t handle the speed and twisted itself to failure, bringing your entire outbound line to a halt.
A high-speed palletiser is one of the most mechanically brutal environments for a cable. A generic “flexible” cable will fail, causing production halts that directly impact OEE. This guide outlines five critical performance tests a cable should pass to survive—so you can specify a solution that improves reliability when correctly applied and installed.
Why Palletisers Are Cable Torture Chambers
Unlike a simple linear gantry, a modern robotic palletiser combines multiple, conflicting stresses at high speed. The main energy chain provides fast linear travel, while the multi‑axis head adds severe bending and torsional (twisting) forces. This combination will quickly expose any weakness in a cable’s design.
Stresses your cable must survive
| Stress | Spec target (guidance) | ÖLFLEX® example |
| Bend Radius | as low as 7.5× OD (≤ 16 mm²); 10× (≥ 25 mm²) | ÖLFLEX® CHAIN 896 P |
| Cycles | up to 10 M (depends on travel & radius; per A2‑1) | ÖLFLEX® CHAIN 896 P |
| Torsion | ±360°/m (robot paths) | ÖLFLEX® ROBOT 900 P (flexing min. bend radius 15× OD) |
| Speed / Accel | up to 10 m/s & 50 m/s² (Extended Line; per A2‑1) | ÖLFLEX® FD 855 P |
| Jacket | PUR outer sheath; abrasion & notch‑resistant | ÖLFLEX® CHAIN 819 P |
Source note: Guidance aligns with LAPP Selection Table A2‑1 and product datasheets for FD 855 P, CHAIN 896 P and ROBOT 900 P. Always confirm limits for the exact part number and size.
See also: ÖLFLEX® Power & Control Cables.
The 5 Critical Performance Tests
Before specifying a cable for your next palletiser, ensure it can pass these essentials.
Test 1: The High‑Speed Bend‑Radius Test
Evaluate the cable’s ability to survive millions of bends at the rated radius without internal damage. Extended‑line chain cables can achieve multi‑million cycles when applied per A2‑1. For reference, ÖLFLEX® FD 855 P has a flexing minimum bend radius of 5× OD.
What to look for
- Class 6 extra‑fine stranding and very short lay lengths
- Non‑woven/fleece core wrapping to stabilise cores
- PUR outer sheath for abrasion/oil resistance
Consequence of failure Exceeding the min bend radius accelerates conductor fatigue and insulation wear, leading to open circuits and unplanned stops.
Test 2: The Torsion Stress Test
Torsion is the twisting force as the head rotates. A torsion‑rated cable such as ÖLFLEX® ROBOT 900 P is designed for ±360°/m torsion (and has a 15× OD flexing bend radius). Use robot‑rated cables on twisting runs; don’t rely on chain‑only cables for 3‑D robot motion.
What to look for
- Special stranding suited for torsion
- PTFE/non‑woven tape wrapping to allow cores to slide under twist
Consequence of failure Non‑torsional cables “corkscrew”—cores bind, insulation deforms, and the cable can jam in the chain.
Test 3: The Speed & Acceleration Test
High speed and rapid acceleration impose large forces on the core. Extended‑line chain cables (e.g., FD 855 P) are specified for up to 10 m/s and 50 m/s² in A2‑1 when applied with the proper radius and travel.
What to look for
- Short lay lengths and non‑woven wraps to control core movement
- PUR sheath to maintain integrity under dynamic load
Consequence of failure Unstable cores can shift, damaging insulation/shields and causing electrical faults.
Test 4: The Abrasion‑Resistance Test
Inside an energy chain the sheath constantly rubs the links. PUR sheaths are preferred for chain duty thanks to abrasion and notch resistance.
What to look for
- PUR sheaths and smooth, pressure‑resistant surface finishes on chain links
Consequence of failure Worn sheaths expose shields/conductors, inviting moisture and conductive debris ingress.
Test 5: The Oil & Chemical‑Resistance Test
Chain cables often see lubricants and cleaners. PUR‑jacketed series like ÖLFLEX® CHAIN 819 P / 896 P and FD 855 P offer broad resistance to many mineral oils and diluted acids/alkalis (check the datasheet for specifics).
What to look for
- Stated resistance to the fluids used on your line; match by datasheet, not by guesswork
Consequence of failure Chemicals can swell or embrittle standard PVC, cracking the sheath and compromising electrical and mechanical integrity.
Quick Answers to Common Questions
What’s the difference between a CHAIN and a ROBOT cable? CHAIN = high‑cycle linear bending in drag chains. ROBOT = designed for added torsion. Robot‑rated cables can run in power chains; chain‑only cables are not for 3‑D torsion.
Why is a PUR jacket better than PVC here? PUR provides higher abrasion/tear and chemical resistance and stays flexible across a wider temperature range—ideal for dynamic duty.
How do I calculate cable length for a drag chain? Follow your chain manufacturer’s formula for the specific chain series and installation (unsupported vs sliding), then add termination allowances.
The Bottom Line: Don’t Let the Wrong Cable Stop Your Line
In a high‑throughput facility, your cables aren’t just components; they’re critical assets. Specify cables that meet the five tests above and you move from reactive break‑fix to proactive reliability.
Book a Palletiser Cable Audit and download our Drag‑Chain Stress Calculator to specify with confidence. Explore ÖLFLEX® drag‑chain cables or talk to a JJ‑LAPP automation expert to find the perfect solution.
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