The Art of the Perfect Cable

We develop optimal cable solutions for our customers. The challenges faced by modern cables and wires are multifaceted: moving applications with more than ten million cycles, severe mechanical and chemical loads, tricky bending radii and space-saving hybrid solutions. For each, HELUKABEL has answers to help you.
To ensure a faultless operation, all new products developed undergo rigorous testing at our R&D centre in Windsbach, near Nuremberg. Here we bend, pull, grind and ignite the cable for all it’s worth. Our special aging ovens are time machines that simulate a cable’s life cycle and far beyond. Tests are performed in accordance with national and international standards, which means the quality is confirmed and guaranteed.

Our test facilities:

  • Torsion test tower for wind power cables
  • Drag chain test equipment (1 m, 3 m, 5 m, 6 m, 18 m, 20 m and 40 m accelerations up to 50 m/s; travel speeds up to 10 m/s)
  • Fire testing equipment
  • Abrasion testing equipment
  • Test facilities for bending and torsion requirements
  • Aging furnaces according to UL, VDE, CSA, HAR, TÜV, CCC

Torsion Tests

Cable during torsion test

Cables applied to industrial robots and other moving machines must often withstand extreme torsional loads. We simulate this type of stress around a cable’s own axis in our testing facilities. This is how we ensure that all materials used are reliable and long-lasting.

See more: Put to the Ultimate Test – Part 1: Torsion Tests

Bending tests

Bending tests

Bending tests are used to evaluate the mechanical strength of cables and wires under bending stress. In practice, frequent directional changes after a while may lead to cable breaks, especially at weak points. With our testing equipment, we simulate various loads and bending radii to ensure that our products reliably withstand the stresses and strains that come with everyday use.

>>See more: Put to the Ultimate Test – Part 2: Bending Tests

Drag Chain Tests

Drag chain tests in the test laboratory

Drag chain cables are always on the move: high accelerations, tight bending radii and constant abrasion are continuous strains on the material. Our drag chain test systems allow us to apply different travel distances and chain radii and therefore simulate various operating conditions.

See more: Put to the Ultimate Test – Part 3: Drag Chain Tests

Abrasion tests

Kink and Abrasion Tests in Testing Laboratories in Windsbach

Cables used in dynamic applications are exposed to a variety of mechanical stresses – including abrasion, for example, due to contact with other machine components. In the long term, this may damage or destroy the insulation of a cable and can even result in cable breaks, malfunctions, short circuits and fires. In our testing laboratories, we therefore run abrasion tests to evaluate the suitability of our sheathing and insulation materials against the demands of everyday use.

>>See more: Put to the Ultimate Test – Part 4: Kink and Abrasion Tests

Kink tests

Kink and Abrasion Tests in Windsbach

Bending loads are part of everyday life for cables and wires in many moving applications. Over time, however, they can irreparably damage sheathing and conductor materials and even lead to a break, which can result in expensive malfunctions, machine failures and fire hazards. We therefore run special kink tests to assess a cable’s resistance and avoid unpleasant surprises when used.

Twister Tests

Drag chain tests in the test laboratory

There are applications where our cables and wires are exposed to torsional and bending
movements at the same time. For this reason, we have the so-called twister test:
this is a torsion and bending test with a special drag chain that simulates the loads
applied in highly dynamic applications. The travel distance and the maximum angle
of rotation are specified by the drag chain.

Torsion Tower for Wind Power Cables


Cables in wind turbines are also exposed to strong torsional forces. This may cause
their mechanical and electrical functionality to deteriorate over time. We check the
torsion resistance of our products in our test tower for wind power cables to prevent
expensive system failures once in use.


HELUKABEL® products meet the following approvals:

BelgiumComité Electrotechnique Belge (CEBEC)
ChinaChina Compulsory Certification (CCC)
DenmarkDanmarks Elektriske Materialkontroll (DEMKO)
GermanyVDE-Prüfstelle (Verband Deutscher Elektrtotechniker e.V.)
GermanyFraunhofer Institut, Produktionstechnik und Automatisierung
EuropeCommunauté Européenne
FranceUnion Technique de I'Electricité
Great BritainBSI British Standards Institution (licensing office)
ItalyIMQ Instituto Italiano de Marchio Qualitá
CanadaCanadian Standards Association (CSA)
NetherlandsNaamloze Vennootschap tot Keuring van Electrotechnische Materialen (KEMA)
NorwayNorges Elektriske Materiellkontroll (NEMKO)
AustriaÖsterreichischer Verband für Elektrotechnik (Zeichenvergabestelle)
RussiaGOST-R Zertifizierung (SGS)
SwedenSvenska Elektriska Materielkontrollanstalten (SEMKO)
SwitzerlandSchweizerischer Elektronischer Verein (SEV)
USAUnderwriters Laboratories Inc. (UL)