This year we had an elevator on a pivot and we saw that the movement points were prone to failure a lot more than the parts that didn’t move. I was wondering if there is a good practice to determine how much wire is needed based on things like the the turn radius or displacement of movement?
The way I would route that sort of wire run is to route the wire at its longest, make sure there’s some slack, and tie off at the nearest fixed points.
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Looking at one of your match videos, it appears you had your wires in couple of nice wiring harnesses that kept the turn radius down to about 2" or less along its length - that should be plenty adequate for what’s fully inside the harness assuming a smooth layout inside.
I suspect your stresses were where the wiring harness attached at the endpoints, as those harnesses were bouncing up and down and side to side pretty loosely. If you didn’t do this already (I couldn’t see enough detail, but I suspect not based on the motion), secure your harnesses to each mounting end using two or more ties spanning at least the diameter of the harness; this should reduce the curvature of the wires at the end of the runs.
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