Most cable failures occur as a result of not choosing the best product for a specific application. By following the guidelines below, designers can help ensure that the cable chosen for an application does not bring about failure and downtime.
Define the environment
Cables must operate in many different industrial environments from clean rooms to harsh locations, each with its own unique demands. Clean rooms require shed-free, low halogen cables while harsh environments like mines need products that are resistant to high temperatures, oils, and chemicals.
Identify application demands
Each application places specific demands on a cable. For example, continuous flexing robots need a cable designed to withstand rigorous movement. Robotic applications are frequently the cause of premature failure in cables that have not been chosen correctly. In continuous flexing applications, use a cable with enhanced flexing capability to maximise performance and machinery productivity. Cables can also be flex-tested by the manufacturer where concerns exist.
Identify oils and chemicals
Many of the oils used in manufacturing are similar to the oils in PVC compounds. Similar oils can attack each other causing PVC to swell, dry out, and crack, resulting in cable failure. If the oils present in an application are known, the best choice of jacket compound can be made. Cable manufacturers should also be able to supply test data showing how cables respond after being exposed to various oils and solvents.
Temperature
Products perform differently at the extremes of temperature. For instance, if the application requires a cable to be flexible at -5°C or lower, a compound good for lower temperatures must be used. Since there are many different material compounds on the market the cable supplier should be able to advise the best solution.
EMI/RFI
Many OEMs run power, signal and data cables side by side, creating the possibility of crosstalk and interference. In such cases, shielded cables can provide protection from interference. For flexing applications, shielded cables that maintain their ability to flex are preferred.
Define the life span
If equipment is only expected to survive one month on the plant floor before replacement then it is not necessary to specify cables that last longer. However, most end-users expect a long life and little downtime from machines, which makes it imperative to evaluate the reliability and longevity of cables and other components.
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