Why Proof Load Testing is Essential for Cable Assemblies

A business can’t truly guarantee the performance of a product unless it has been objectively tested. There are plenty of ways to fabricate an item with quality materials, but there is no real assurance that the product will perform as expected over time until it is fully tested under real conditions. This is why quality furniture makers, for example, have devised ways of using machines and robots to sit down on a chair or pull a drawer 500,000 times to confirm that the given part will perform as expected for more than a reasonable lifetime.

When it comes to cable assemblies, the method of quality testing and assurance is done via proof load testing. The process ensures that both the cable tensile and the cable connectors hold up to far more than the minimum performance expected. Even data cables have torsion testing applied! After all, if things just performed to the minimum, then average use would easily exceed that metric. A cable assembly typically has fittings on each end, which can be weak points even if the cable itself is strong enough to hold the intended load. This can cause a fitting to slip off or break, leading to mechanical failure of the cable assembly within your application.

Proof load testing is a process used to verify the strength and durability of cable assemblies. The goal of proof loading is to identify weaknesses in the assembly, such as minor line stretch, hardware slippage, or minute wire breakage, without breaking the cable. During this test, each assembly is subjected to tension on a flat testing field. The tension is typically applied at 60% of the rated breaking strength of the mechanical cable.

An assembly that has succeeded a proof load test is put through a separate test to determine its true breaking point. This second test, a destructive test, ensures that the breaking point occurs well above the maximum load a user would typically apply. By confirming the breaking point, Sava's engineers can guarantee that the assembly will perform safely within the established safety parameters. These tests associated with the proof loading methodology ensure that each Sava cable assembly meets the highest safety and performance expectations.

Proof load testing serves two primary purposes:

1. Ensuring Integrity: It confirms that the cable assembly can withstand more than the minimum expected performance, ensuring reliability and safety.
2. Prestressing the Cable: This process removes constructional stretch, reducing the need for frequent adjustments and maintaining proper tension in motion control systems.

After assemblies are proof loaded, subsequent handling should be minimized to preserve the prestressing effect. If stretch is critical in your application, we suggest contacting Sava's engineering department for further information.

By identifying and addressing potential weak points early, proof load testing helps prevent mechanical failures and ensures the overall performance and safety of cable assemblies.

At Carl Stahl Sava Industries, we are leaders in proof load testing, complying with ISO 9001:2015, FDA, ITAR, REACH, and RoHS standards. Our rigorous testing protocols and advanced techniques ensure that every cable assembly meets the highest standards of quality and durability. In addition to proof load testing, we employ other testing methods such as torsion testing for data cables. Our multi-faceted testing and quality checks throughout production help deliver a top-quality product line that sets the benchmark for the industry.

Proof load testing is essential to ensure the integrity, reliability, and performance of cable assemblies. Sava's cable experts are committed to maintaining the highest standards of quality through rigorous testing and continuous improvement. Contact us today to learn more about our custom cable solutions®.