Kabelrups berekenen: in zes stappen van kabels tot lengte

Begin bij het kabelpakket. Daaruit volgen de binnenhoogte (dikste kabel × 1,1), de binnenbreedte (som van alle diameters met speling) en de buigradius (7,5 × dikste kabel). Met de rijweg en het vaste punt bereken je de lengte: halve rijweg plus π × radius plus twee schakels, afgerond op hele schakels.

Hoe bereken je de lengte van een kabelrups?

Met het vaste punt in het midden: halve rijweg plus π maal de buigradius plus twee keer de steek. Met het vaste punt aan het eind telt de hele rijweg. Rond daarna naar boven af op hele schakels.

Hoeveel speling moet je rekenen rond kabels in een kabelrups?

Op deze site wordt gerekend met 10% op de diameter van kabels en 20% op slangen. Kabels zetten uit door warmte en slangen zwellen onder druk; met speling blijven ze vrij liggen.

Wat is een goede vulgraad voor een kabelrups?

Onder 85% is goed, tussen 85 en 90% is krap en boven 90% is de rups te vol. Controleer daarnaast of alle leidingen naast elkaar in de binnenbreedte passen.

Waar zet je het vaste punt van een kabelrups?

Als het kan in het midden van de rijweg. De rups is dan ongeveer de helft van de rijweg korter dan met het vaste punt aan het eind.

Kan ik mijn berekening laten controleren?

Ja. Wisman controleert berekeningen uit de rekentools en de Kabelrups-configurator kosteloos. Stuur je uitkomst mee met je aanvraag.

Calculating a cable carrier: from cables to length in six steps

Short answer

Start with the cable package. It gives you the inner height (thickest cable × 1.1), the inner width (sum of all diameters with clearance) and the bending radius (7.5 × thickest cable). With the travel length and the fixed point you calculate the length: half the travel length plus π × radius plus two links, rounded up to whole links.

Calculating a cable carrier: six steps from cables to length

You calculate a cable carrier in a fixed order: cable package, inner dimensions, fill level, bending radius, length and finally layout and installation height. Each step uses the result of the previous one. These are the same calculation rules that the Cable carrier configurator and the separate calculators use.

In this article we work through one example from start to finish. That way you can see exactly where each number comes from, and repeat it with your own cables.

Step 1: list the cable package

Make a list of all cables and hoses with their outer diameter and, if you know it, the minimum bending radius from the datasheet. Also note which lines are hoses: they get more clearance.

Our example:

Line	Quantity	Diameter
Motor cable	1	20 mm
Control cable	4	10 mm
Data cable	1	8 mm
Pneumatic hose	1	12 mm

Also think about spare capacity. Adding a cable later is often harder than leaving room right away. If you are not sure your cables are suitable for movement, first read which cables belong in a cable carrier.

Step 2: calculate the inner height and inner width

Cables and hoses must not lie tight. That is why the site uses an effective diameter:

Cable: diameter × 1.10
Hose: diameter × 1.20

The minimum inner height is the largest effective diameter. The minimum inner width is the sum of all effective diameters.

In the example: motor cable 20 × 1.1 = 22 mm, control 4 × 11 = 44 mm, data 8 × 1.1 = 8.8 mm and hose 12 × 1.2 = 14.4 mm. That gives a minimum inner height of 22 mm and a minimum inner width of 89.2 mm. Dividers come on top of that if you want to separate the package.

A type that fits is the UNIFLEX Advanced 1455: inner height 26 mm, available in inner widths of 25, 38, 58, 78, 103 and 130 mm. The next width above 89.2 mm is 103 mm. Also check the maximum cable diameter of the type: for the 1455 it is 20.5 mm, so the 20 mm motor cable fits.

Step 3: check the fill level

The fill level shows how much of the cross-section the lines take up:

Fill level = Σ π × (d_eff / 2)² / (Bi × Hi)

Below 85% is good, between 85 and 90% is tight and above that the carrier is too full. In the example, the combined area of all lines is about 984 mm². The cross-section of the carrier is 103 × 26 = 2678 mm². The fill level is then about 37%, well within the limit.

Note the difference between the two checks. A width of 78 mm gives a fill level of 49%, but is still too narrow: the lines do not fit side by side. That is why the calculator looks at both. How to divide heavier or mixed packages is explained in fill weight and dividers.

Calculate it yourselfCalculate fill levelRequired inner dimensions and fill levelCalculate it

Step 4: choose the bending radius

The radius is at least 7.5 times the thickest diameter, or the datasheet value if that is larger. With many movements per day, use 10 times.

In the example: 20 × 7.5 = 150 mm minimum and 20 × 10 = 200 mm generous. The UNIFLEX Advanced 1455 has both radii in its list. If the hose datasheet states a larger value, that one takes precedence. All details are in determining the bending radius.

Step 5: calculate the length in whole links

The length depends on the travel length (S), the radius (KR), the pitch (p, the length of one link) and the position of the fixed point:

Fixed point in the middle: L = S/2 + π × KR + 2 × p
Fixed point at the end: L = S + π × KR + 2 × p

Then round up to whole links. The UNIFLEX Advanced 1455 has a pitch of 45.5 mm. With a travel length of 3000 mm, KR 150 and the fixed point in the middle:

(01)3000 / 2 = 1500 mm
(02)π × 150 = 471 mm
(03)2 × 45.5 = 91 mm
(04)Together about 2062 mm, which is 45.3 links
(05)Rounded up: 46 links, 2093 mm

Variant	Raw length	Links	Length
Fixed point middle, KR 150	2062 mm	46	2093 mm
Fixed point middle, KR 200	2219 mm	49	2229,5 mm
Fixed point end, KR 150	3562 mm	79	3594,5 mm

With the fixed point in the middle, the carrier is therefore about 1.5 metres shorter. That saves weight, space and cable length.

Calculate it yourselfCalculate cable carrier lengthLength and number of links from travel length and radiusCalculate it

Step 6: check installation height and layout

The installation height is roughly 2 × KR + outer height. The UNIFLEX Advanced 1455 has an outer height of 36 mm, so with KR 150 that is 336 mm and with KR 200 it is 436 mm. Also check the outer width: on this carrier it is 16 mm more than the inner width, so 119 mm at an inner width of 103 mm.

Then the layout. Each type lists a maximum travel length, speed and acceleration for self-supporting and for gliding use. For the 1455 the type data give a self-supporting travel length of up to 4.8 m, so 3 m is within that. The fill weight, the speed and the environment (chips, heat, outdoors) further determine the design. The difference between the two layouts is explained in self-supporting or gliding.

Rather not do the maths yourself?

Enter your cables, travel length and fixed point in the Cable carrier configurator. It runs through these six steps, filters the types that fit and shows the length, installation height and checks per type. If you also want to draw the cables in the cross-section, with dividers and a shelf, use ChainLogic. A specialist checks the result free of charge.

For long travel lengths or heavy packages you are more likely to end up with series such as the TKHP or with steel cable carriers. Which dimensions you need to know for that is explained in cable carrier dimensions explained. Got everything lined up? Request a quote directly.

Calculate it yourselfCable carrier configuratorCalculate, select and assemble a cable carrierOpen the cable carrier configurator

Frequently asked questions

How do you calculate the length of a cable carrier?

With the fixed point in the middle: half the travel length plus π times the bending radius plus twice the pitch. With the fixed point at the end, the full travel length counts. Then round up to whole links.