Introduction

Walk into any modern South African factory—whether it’s a Johannesburg packaging plant, a Durban automotive line, or a Rustenburg mineral processing facility—and you’ll find machines moving with incredible speed and accuracy. Robotic arms swing thousands of times per hour, conveyor belts run 24/7, and sensors continuously report back to control systems with pinpoint accuracy.

But behind every movement, every position reading, and every feedback loop, there’s one quiet component working harder than the rest:

➡️ The drag-chain high-flex encoder/feedback cable.

And among them, the HIFLEX LiPC(DY)C11Y has earned a reputation for being “the cable that does not get tired.”

This article dives deep into:

• What makes a cable genuinely high-flex

• The complete technical parameters

• Cable structure and materials

• Application scenarios in South Africa

• Real case studies

• Expert-level explanations and FAQs

By the end, you’ll know exactly why engineers across South Africa rely on this cable for accuracy, durability, and peace of mind.

What Makes a Drag Chain Cable Truly “High-Flex”?

In high-speed automated systems, the cable is not merely a conductor—it’s a mechanical component.

Every second, drag chain cables experience:

• Constant bending

• Repetitive sliding

• Torsion and vibration

• Sudden acceleration and deceleration

• Exposure to oil, dust, and cleaning chemicals

In South African industries—especially mining, automotive manufacturing, and food/beverage processing—the operating environment can be brutal:

• Coarse dust from ore processing

• Abrasive sand in outdoor installations

• High humidity in coastal plants

• Heavy EMC interference from motors

• Harsh lubricants and hydraulic oils

To survive thousands of bending cycles per hour, a cable must have:

✔ Ultra-fine stranded conductors
✔ Tough yet flexible insulation
✔ EMC-optimised shielding
✔ A sliding-ready, abrasion-resistant outer sheath
✔ High resistance to chemicals and oils

The HIFLEX LiPC(DY)C11Y is specifically engineered for this mission.

Technical Specifications of HIFLEX LiPC(DY)C11Y

This section gives an engineering-level breakdown of the cable’s performance.

Electrical Performance

Why this matters:

• Low capacitance ensures stable encoder signals over long runs—critical for fast-moving systems.

• High insulation resistance prevents signal drift and noise.

• 1500 V test voltage demonstrates strong insulation integrity.

In plants where dozens of drives, VSDs, and motors operate simultaneously (common in SA automotive and mining operations), EMC reliability is essential. The cable is designed with this in mind.

Mechanical Performance

Real-world meaning:

• The cable can handle very fast drag chain cycles, such as in packaging or pick-and-place robots.

• High acceleration tolerance makes it suitable for dynamic servo and encoder systems.

• The bending radius is carefully optimised to prevent premature conductor fatigue.

Environmental Performance

Why this is perfect for SA conditions:

• SA temperature ranges—from cold Free State mornings to hot Mpumalanga mines—fit within the cable’s window.

• Resistance to hydraulic oils is essential in mining and heavy industry.

• Radiation tolerance is useful in specialised mineral processing environments.

Cable Structure in Detail (Professional Engineering Breakdown)

The cable’s reliability comes from carefully engineered internal design.

Ultra-Fine Stranded Copper Conductors

The conductor designs are optimised for repeated flexing:

• 0.14 mm² = 18 × 0.10 mm

• 0.50 mm² = 16 × 0.20 mm

• 1.00 mm² = 32 × 0.20 mm

These extremely fine strands bend without micro-cracking, preventing premature failure.

TPE Insulation and Core Pairing

Each core is insulated with high-grade TPE, chosen for:

• Flexibility

• Thermal stability

• dielectrical strength

Core identification:

0.14 mm² pairs

• Yellow + green

• Grey + pink

• Red + blue

1.0 mm² pair

• White + brown

  Twisted Pairs:

Twisting is essential for noise-free signal transmission, especially for:

• Encoders

• Feedback sensors

• Low-voltage instrumentation

High-Density Tinned Copper Braided Shield

Coverage: 85%

This protects against EMI from:

• High-power motors

• VSDs

• Inductive loads

• Welding equipment

• Crushers and feeders (mining)

The tinned braid also provides corrosion resistance—important in coastal or humid environments.

Non-Woven Wrapping Layer

This layer reduces internal friction, extending service life in drag chains.

Special PUR Outer Sheath (Black RAL 9015)

This is one of the cable’s greatest strengths.

PUR advantages:

• High sliding capability inside drag chains

• Excellent oil and chemical resistance

• High wear resistance

• UV stability

• Impact resistance

Compared with PVC or TPE sheaths, PUR lasts significantly longer in:

• Mining plants

• Automotive assembly lines

• Food processing equipment

• Port automation systems

Dimensional Data and Mass

These designs are common in encoder and feedback loops where both signal and auxiliary power cores are required.

Key Properties and Advantages

Exceptional Flex Life

The combination of ultra-fine copper, TPE insulation, and PUR sheath ensures the cable withstands millions of bending cycles.

High EMC Reliability

The 85% tinned braid ensures precise feedback even in:

• Large conveyor plants

• Smelters

• Mineral processing lines

• Metalworking factories

Chemical, Oil, and Weather Resistance

Ideal for SA’s:

• Mining oils

• Hydraulic systems

• Dusty outdoor operations

• High-humidity coastal zones

Stable, Predictable Signal Transmission

Low capacitance + twisted pairs = accurate encoder readings.

Applications in South Africa

The cable is widely used in dynamic equipment across SA.

Industrial Automation

• CNC machining centres

• Pick-and-place robots

• High-speed packaging machines

• Automated conveyors

Automotive Manufacturing

Used in plants such as:

• Rosslyn (Pretoria) – BMW, Nissan

• Gqeberha (Port Elizabeth) – VW

• East London – Mercedes-Benz

These plants rely heavily on drag chain systems for robotic welding, painting, and assembly.

Mining and Mineral Processing

Perfect for:

• Ore sorting sensors

• Conveyor tracking systems

• Automated sampling machines

• Crushers with feedback loops

• Smart mineral processing lines

Logistics and Warehousing

• AS/RS shuttles

• Sorting conveyors

• Robotics for parcel handling

Johannesburg Packaging Plant

Background

A high-speed packaging plant in Johannesburg was experiencing:

• Intermittent encoder signal losses

• Frequent cable replacements

• Downtime costing tens of thousands of rand per month

Root Cause

PVC-sheathed cables were failing due to:

• Friction in the drag chain

• EMC interference

• Mechanical fatigue from rapid cycles

The HIFLEX Solution

The plant replaced the cables with HIFLEX LiPC(DY)C11Y.

Results After 3 Months

✔ Encoder errors dropped drastically
✔ Signal stability improved
✔ Maintenance downtime reduced by 40%
✔ Drag chain cycles increased significantly without insulation wear

Engineers' Feedback

“Once we switched to the PUR-sheathed HIFLEX cable, the machine stopped giving random position errors. It simply works.”

How South African Engineers Should Select a High-Flex Encoder Cable

Key factors:

Movement Profile

• Length of drag chain

• Bending radius

• Cycle frequency

Temperature

• Outdoor installations

• Hot mining environments

Chemical Exposure

• Lubricants

• Hydraulic oils

• Coolants

EMC Conditions

• Strong interference requires high-coverage shields

Cable Length

• Capacitance affects encoder performance

Manufacturer Credibility

A proven cable reduces downtime and saves long-term costs.

Installation and Handling Guidelines

Respect the Minimum Bending Radius

Never exceed 10 × OD.

Provide Proper Slack

Avoid stretching or tension.

Avoid Sharp Edges

Use protective ducts where necessary.

Keep Drag Chains Clean

Dust or debris increases friction.

Routine Inspections

Early signs of wear:

• Flattened sheath

• Discolouration

• Exposed braid

Frequently Asked Questions (FAQ)

Can this cable handle 24/7 continuous flexing?

Yes. It is designed for millions of cycles in high-speed drag chain systems.

Is the 85% shielding enough for environments with heavy motors?

Absolutely. It exceeds typical shielding needs in SA mining and automotive plants.

Can the cable be used outdoors in high-UV regions like Northern Cape?

Yes. The PUR sheath offers excellent UV and weather resistance.

Is it resistant to hydraulic and mining oils?

Yes, fully compliant with VDE 0472-803 A/B.

What is the typical service life?

This depends on the drag chain length and cycle rate, but users report significantly longer lifetimes than PVC/TPE cables.

How does it compare to PVC-sheathed cables?

PVC is cheaper but fails much faster. PUR outperforms PVC in flexibility, oil resistance, and abrasion.

Is it suitable for long encoder cable runs?

Yes, its low capacitance supports stable signals over extended distances.

Conclusion

South Africa’s industries—from mining to automotive to logistics—rely on precision, speed, and reliability. A small cable failure can halt an entire assembly line or conveyor system.

The HIFLEX LiPC(DY)C11Y stands out because it offers:

• Mechanical durability

• Excellent EMC protection

• Outstanding chemical and oil resistance

• High flexibility for extreme motion

• Proven real-world performance in SA plants

For engineers seeking long-lasting, reliable performance in drag-chain applications, this cable is a true industry-grade solution that delivers stability, accuracy, and operational continuity.