Cable Carriers vs. Festoon systems

In moving machinery and automated systems, proper cable guidance is essential. Two common solutions are cable carriers (energy chains) and hanging cable bundles (freely hanging loops). But when should you choose one over the other? This article compares both systems across five key criteria: motion control, wear, space usage, cost, and maintenance. 1. Motion control and positioning Cable carrier: Provides controlled, repeatable movement of cables and hoses. Cables follow a defined path and do not twist or rub. Hanging cable bundle: Cables hang freely in a loop and move independently. This can work for simple or slow movements but is less predictable for fast or complex motions. Advantage: Cable carrier 2. Protection and wear Cable carrier: Protects cables from abrasion, vibration, impact, and external factors — ideal for industrial environments or frequent motion cycles. Hanging cable bundle: Cables are exposed and may rub against structures or each other, leading to faster wear or failures. Advantage: Cable carrier 3. Space usage Cable carrier: Requires fixed length and bend radius, which can take up more space, especially with long travel distances. Hanging cable bundle: Takes up less space when stationary, suitable for simple linear movements with limited travel. Advantage: Hanging cable bundle (for compact or simple setups) 4. Costs (initial and total) Cable carrier: Higher initial cost due to components and installation, but lower maintenance and longer cable life. Hanging cable bundle: Cheaper upfront and easier to install, but potentially more expensive long-term due to cable damage and replacement. Advantage: Cable carrier for long-term value; hanging cable bundle for low-budget, low-load use 5. Maintenance and reliability Cable carrier: Less risk of cable breakage and predictable movement. Easy to inspect and replace in sections. Hanging cable bundle: Greater risk of hidden damage, such as internal breaks. Harder to monitor unless visibly worn. Advantage: Cable carrier Conclusion For applications with frequent motion, high wear risk, or reliability demands, a cable carrier is usually the better option. For low-stress, low-budget, or simple linear movements, a hanging cable bundle can suffice. Not sure which cable carrier fits your setup? Start the cable carrier filter and find the right match.