Hi,
There is a sensor on SERVO that need 3 pieces wire follow the sweep in a small area.
Thanks
Adam

 

What size/type servo?
How small is small?
What sweep angle?

 

Are you sure you need it to be flexible? Sometimes it is better if the insulation is stiffer, as it makes the wire bend over a bigger radius instead of bending abruptly at a certain point.

 

The first thing that came to mind was the wires for record player pickup arms. On Amazon I found "TURNTABLE FLEXIBLE VERY THIN WIRES TO REWIRE ANY TONEARM. SET OF 4" but at an outrageous price. But if you still have a nearby dealer in radio/TV/stereo repair parts, that's a good place to look. Or look for flexible wires inside a headphone cable or USB cable or whatever e-waste you have lying around.

 

Silicone insulated wire is common in the R/C world. It's more flexible than PVC insulated.

 

I bought 100m of this for making flexible test leads:

I bought it 6 years ago for less than $20 with free shipping. I'm a bit surprised the store I bought it from is still selling it.

 

I used to work at a place that used a wire called "Superflex" for production line cables that flexed constantly and had to last a year. Not sure where they purchased it, but that will work very well for the servo sensor application.

 

I used to work at a place that used a wire called "Superflex" for production line cables that flexed constantly and had to last a year. Not sure where they purchased it, but that will work very well for the servo sensor application.

It might have been from Galaxy or Igus.

 

Are you sure you need it to be flexible? Sometimes it is better if the insulation is stiffer, as it makes the wire bend over a bigger radius instead of bending abruptly at a certain point.

Thanks.
its true some times the stiff wire better. in my case here is a very small space, I striped the cable of RS232 and used the wire inside which is good for now. the red piece is 24AWG.

 

Th critical part is to provide strain relief at the end of of the wire that is fixed in position so the solder joint or terminal connection isn’t flexed. It is also helpful to provide enough slack often with a loop, that even the strain relief takes little of the flexing which is instead spread over the larger area of the loop. Take care, though, not to make such a loop to small because that defeats the purpose. I space is tight the loop can be just a half loop that proves a way to distribute the flexing.

 

How much flexing does that wire actually need to do? And what sort of life-span is required? What happens when one of the conductors fails? If the sensor is in the feedback loop for a servo it may be that the results of losing that feedback are very undesirable.
In fact, it is important to understand what happens when one of the conductors does break, and certainly with constant flexing that will happen eventually. I have seen a rather expensive result of a servo failure caused by a limit switch mounting screw becoming loose. Fortunately for me it was not in the section that I had even touched. But it cost somebody two days of lost production in addition to the cost of replacing the broken parts.

 

It might have been from Galaxy or Igus.

Igus is the gold standard for continuous flex cable. I would recommend this hands down, however it may be difficult to find in a single short length as I assume TS needs. Or not, I don't know; I haven't checked.

 

Th critical part is to provide strain relief at the end of of the wire that is fixed in position so the solder joint or terminal connection isn’t flexed. It is also helpful to provide enough slack often with a loop, that even the strain relief takes little of the flexing which is instead spread over the larger area of the loop. Take care, though, not to make such a loop to small because that defeats the purpose. I space is tight the loop can be just a half loop that proves a way to distribute the flexing.

Thanks.

 

How much flexing does that wire actually need to do? And what sort of life-span is required? What happens when one of the conductors fails? If the sensor is in the feedback loop for a servo it may be that the results of losing that feedback are very undesirable.
In fact, it is important to understand what happens when one of the conductors does break, and certainly with constant flexing that will happen eventually. I have seen a rather expensive result of a servo failure caused by a limit switch mounting screw becoming loose. Fortunately for me it was not in the section that I had even touched. But it cost somebody two days of lost production in addition to the cost of replacing the broken parts.

Thanks.