Selecting the correct cable type

FOR YOUR APPLICATION

Data transmission plays a key role in selecting the right cable type. To ensure reliable and efficient communication, various aspects such as transmission rate, signal quality, and loss minimization must be carefully considered.

• Transmission rate and bandwidth: The required data transmission rate is a decisive factor in cable selection. Applications with high data rates, such as Ethernet networks or industrial fieldbuses, require cables with high bandwidth. For example, CAT6 or CAT7 cables offer high transmission rates and are ideal for Gigabit Ethernet applications. For applications that need to transmit large amounts of data over long distances, fiber optic cables may be the best choice, as they enable virtually loss-free transmission over long distances.
• Signal quality and susceptibility to interference: Signal integrity is particularly important in environments with a high risk of electromagnetic interference (EMI). Shielded cables (e.g., S/FTP or SF/UTP) offer better protection against electromagnetic interference and ensure stable data transmission. In extremely interference-prone environments, it may also be necessary to use double-shielded cables or consider fiber optic solutions, as these are insensitive to electromagnetic interference.
• Loss-free transmission: In applications where data integrity is critical, such as in medical technology or sensitive measurement systems, cables with low signal loss are required. Here, attention should also be paid to impedance matching in order to minimize reflections and signal losses.

When selecting cables for specific applications, it is important to consider temperature resistance, moisture resistance, and chemical resistance. These properties ensure that the cable will function reliably, regardless of whether it is exposed to extreme temperatures, moisture, or chemical substances.

Cables must be able to operate within the temperature ranges to which they are exposed in their application. In extreme temperatures, whether high or low, it is important to choose a cable that is designed for these conditions. Silicone cables, for example, are known for their high temperature resistance and are well suited for applications near heat sources. On the other hand, Teflon-coated cables offer excellent performance at extremely low temperatures.

In environments with high humidity or direct contact with water, such as outdoor areas or industrial washing facilities, cables with waterproof or moisture-resistant sheathing are required. These cables prevent water from penetrating, which could lead to short circuits or corrosion. Rubber-sheathed cables often offer good moisture resistance, while polyurethane (PUR) or specialized TPE sheathing can be used for extreme conditions.

If the cable is used in an environment exposed to chemicals or solvents, the cable sheathing material must be resistant to these substances. Cables with sheathing made of special plastics such as fluoropolymers (e.g., PTFE) offer high resistance to chemicals and are ideal for use in the chemical industry or in laboratory environments.

Flexibility, bending radius, and torsion resistance are crucial for dynamic applications in which cables are frequently moved, bent, or twisted.

• Dynamic applications: Flexibility is crucial for applications in which the cable is frequently moved, such as in robots, drag chains, or moving machine parts. Cables with a tight bend radius and high flexibility can withstand repeated movements without breaking the wires or damaging the sheathing. Highly flexible drag chain cables are designed to withstand tens of thousands of bending cycles in a drag chain.
• Bending radius and service life: Another important aspect when selecting a cable is the minimum bending radius specified by the cable manufacturer. This defines how much a cable can be bent without being damaged. A bending radius that is too tight can damage the internal conductors and lead to premature cable failure. It is important to consider the bending radius both during the planning phase and during installation in order to maximize the service life of the cable.
• Torsion resistance: In applications where the cable is not only bent but also twisted, such as in robot joints, the cable's torsional capacity is crucial. Cables designed for such applications have special constructions that prevent the inner wires from twisting and breaking. Such cables generally have a longer service life.