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Wire Bending Life Testing
Wire Bending Life Testing is a crucial durability test designed to evaluate the flexibility, ductility, and endurance of electrical and communication cables subjected to repeated bending cycles. This test simulates real-world mechanical stresses to ensure cables retain their functional integrity and mechanical reliability throughout their service life.
The primary purpose of this test is to:
- Assess the mechanical robustness of cables under continuous flexing
- Ensure long-term durability for cables used in dynamic environments
- Verify compliance with national and international standards
Common application areas:
- Electrical wiring in consumer electronics and appliances
- Robotic and automation cable systems
- Automotive harnesses
- Construction and infrastructure cabling
- Data and communication cables
| Parameter | Specification |
|---|---|
| Bending Angle | 90° per cycle |
| Bending Rate | 60 cycles per minute |
| Bending Radius | 25.4 mm |
| Applied Load | 500 g |
| Cycle Termination | Until conductor failure or predefined cycle threshold (e.g., 10,000 cycles) |
Test Setup Overview
- Cable is fixed at one end, while the other is connected to a movable arm or actuator.
- The arm bends the cable alternatively to ±90°, simulating operational movement.
- A 500 g weight is applied to ensure consistent tension.
Bending continues at 60 cycles/min until:
- Electrical continuity is lost
- Mechanical failure occurs (e.g., conductor fracture, insulation cracking)
- Specified number of cycles is reached
Evaluation Criteria
- Pass: No electrical discontinuity, cracking, or deformation after the required number of cycles (e.g., ≥10,000 cycles)
- Fail: Breakage of conductor, insulation damage, or loss of signal continuity before reaching the minimum cycle threshold
Standards Followed:
- IEC 60811-507
- UL 2556
- ASTM D3032
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