In harsh industrial environments such as mining, automation, robotics, and shipyard/marine, cables must withstand constant movement and continuous flexing. If cables fail, it can lead to costly downtime, equipment malfunctions, and safety hazards. That’s why industrial cable manufacturers rely on rigorous testing methods—such as the Rolling S-Bend Test—to verify durability and performance.
What Is the Rolling S-Bend Test?
The Rolling S-Bend Test is a specialized wire and cable testing method that evaluates a cable’s ability to endure repeated bending and flexing without failure. This test is critical for applications requiring high-flex cables, such as robotics, automation, and heavy machinery. The test simulates real-world conditions found on festoon systems and cable reels. This helps manufacturers design cables that can withstand mechanical fatigue from repeated motion and continuous flexing.
Watch our video to see it in action and learn more from our ATPC Engineer.
How Does the Rolling S-Bend Test Work?
The Rolling S-Bend Test for cables follows a structured process to measure durability:
- Continuous bending: The cable is repeatedly bent in an “S” shape to test flexibility. Tension and radial bending forces are applied to mimic real-world conditions.
- Endurance cycles: The test continues until the cable reaches the expected lifespan or fails.
- Performance analysis: Results assess conductor and insulation/jacket integrity.
Why Is the Rolling S-Bend Test Important for Industrial Cables?
Industries that depend on high-flex and long-lasting cables require assurance that their products will withstand extreme conditions. The Rolling S-Bend Test helps provide:
- Extended cable lifespan: Reduces premature wear and costly replacements.
- Reliable power and data transmission: Prevents system failures in automation and industrial operations.
- Compliance with industry standards: Ensures cables meet safety and performance requirements.
- Increased operational safety: Reduces the risk of electrical failures and downtime.
Choosing the Right Cables for High-Flex Applications
The S-Bend Test simulates real-world conditions where cables undergo repeated bending, flexing, and tension while maintaining performance and durability. Here are a few examples of how it applies to key industries:
✅ Robotics & Automation (3-axis Gantry Robots): Robotic arms and automated machinery require flexible cables that can withstand continuous movement without failure. The S-Bend Test ensures cables can endure repeated bending and flexing, preventing costly downtime.
✅ Material Handling & Cranes (Festoon Systems): In warehouses, ports, and factories, festoon cables are subjected to constant movement along tracks. The S-Bend Test verifies their ability to handle repetitive bending without degradation.
✅ Mining & Heavy Equipment (Cable Reels): In mining, construction, and industrial settings, cable reels must manage tension and radial bending as they extend and retract. The S-Bend Test ensures the cables remain durable under these harsh conditions.
✅ Conveyor Systems (Telescopic Conveyors): In manufacturing and distribution centers, cables powering conveyor belts undergo continuous movement and stress. The test ensures cables maintain integrity despite repetitive bending.
By testing cables under extreme bending conditions, the S-Bend Test guarantees performance and longevity in demanding applications, ensuring safer, more reliable operations across industries.
Explore High-Flex, Durable Cables for Your Application
At Amphenol TPC Wire & Cable, we engineer industrial cables designed for flexibility, durability, and superior performance. Our cables undergo rigorous testing, including the Rolling S-Bend Test, to ensure they withstand harsh environments, repeated motion, and mechanical stress.
Whether you need power cables, data cables, or custom-engineered solutions, our team at Amphenol TPC Wire & Cable provides reliable, tested solutions for automation systems, mining operations, shipyards, and more. Contact us today to learn more about how our cables can enhance the reliability and efficiency of your operations.
