The Challenge

Tow cables face significant shock loads in the field when vehicles are stuck, often reaching the upper limits of material strength. The end fittings must withstand the wire rope’s break strength. Lexco^® Cable was approached by a customer to develop a more robust tow cable solution that could withstand these extreme conditions. Initially, Lexco Cable worked from an outdated drawing with missing process notes and information. This required extensive collaboration between Lexco Cable and the customer to support their requirements and revisions.

The Solution

To address these challenges, Lexco^® Cable pre-stretched each tow cable assembly to ensure it met length tolerance in both relaxed and load conditions. This process involved applying precise tension to each cable to eliminate any potential slack that could affect performance. Additionally, a corrosion prevention compound was applied to the wire rope to prevent rust, ensuring longevity and reliability in harsh environments. For added quality assurance, each assembly was engraved with an identifier for traceability, allowing for easy tracking and verification. Extensive research and development were conducted to qualify the assembly process and outcomes, including rigorous testing under simulated field conditions.

Results

As a result of these efforts, Lexco^® Cable delivered tow cables that met all customer requirements as per the latest revisions. Special packaging was used to protect the assemblies, ensuring they remained intact during transport and storage. Compliance was certified for several stringent characteristics, including:

• Diameter
• Material
• Construction
• Finish
• Strength
• Length after proof-load
• Traceability

This comprehensive approach ensured that the tow cables were reliable, durable, and met the highest industry standards.