A well reowned aerial work platform company, encountered significant challenges with the installation of heavy-duty cables in their production facilities. Despite their industry expertise, the company's installation practices did not align with industry standards or best practices, leading to premature cable failures and costly downtime.
The improper installation manifested in several ways:
Insufficient Bend Radius: Cables were bent too tightly, exceeding the recommended minimum bend radius. This placed excessive stress on the cable's internal conductors and insulation, leading to accelerated wear and tear.
Lack of Separation: Cables were not properly separated within cable carriers, resulting in tangling and abrasion. This further exacerbated the wear and tear issue.
Incorrect Fixation: Cables were not fixed according to the specific requirements of the application, causing undue stress and strain on the cable.
ECHU Wire and Cable, recognizing the impact of improper installation on cable performance and longevity, offered its on-site assessment service to the company. ECHU's experienced engineers conducted a thorough evaluation of the company's cable installation practices, identifying key areas for improvement.
ECHU's engineers provided the following recommendations:
Eliminate Cable Ties: Remove cable ties from the cable carrier's upper bracket to allow for free movement and prevent stress concentration.
Standardize Cable Lengths: Establish a standard for the length of cable reserved for movement at fixed points, ensuring adequate bend radius and preventing the cable from dragging on the ground.
Accommodate Vertical Twisting: Allow sufficient slack for vertical twisting motion or install a corrugated tube to protect the cable during twisting.
By implementing ECHU's recommendations, the platform company achieved a dramatic improvement in cable service life. The company reported a fivefold increase in the lifespan of their heavy-duty cables, resulting in significant cost savings and reduced downtime.
The optimized cable installation also yielded additional benefits:
Enhanced Safety: Proper installation reduced the risk of electrical hazards and equipment damage caused by cable failures.
Improved Efficiency: Reduced downtime and maintenance requirements led to increased operational efficiency.
Long-Term Cost Savings: The extended cable service life resulted in substantial long-term cost savings for their company.
We've seen a significant increase in cable lifespan and a reduction in maintenance costs. ECHU's on-site assessment was thorough and incredibly beneficial for our operations.
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