How to Choose Industrial‑Grade Flexible Cables

Table of Contents

• 1. Understand the Application Environment
• 2. Select the Right Jacket Material
• 3. Choose Suitable Conductor Structure
• 4. Assess Shielding and Flexibility
• 5. Confirm Compliance with Standards
• 6. Evaluate Mechanical & Electrical Performance
• Summary Table

1. Understand the Application Environment

Identify the conditions the cable will face—such as exposure to oil, chemicals, UV, extreme temperatures, abrasion, or continuous motion. Continuous-flex cables are essential for applications like robotics, conveyors, and moving machinery.

2. Select the Right Jacket Material

Choose based on environmental demands:

• PVC: Cost-effective, moisture-resistant, common in general use.
• PUR: Excellent abrasion, oil, chemical, and modest temperature resistance (–40 to 80 °C).
• TPE/TPU: Superior flexibility, UV and cold resistance (–50 to 125 °C), >10 million flex cycles.
• FEP/Silicone: Ideal for high-heat/fire-risk environments; not covered extensively here.

3. Choose Suitable Conductor Structure

For frequent bending or flexing, select cables with high-strand-count stranded conductors (IEC Class 5 or 6) to resist fatigue better than solid cores.

4. Assess Shielding and Flexibility

Use braided or combined foil+braid shields to balance EMI protection and flexibility—ideal for industrial signal and data applications.

5. Confirm Compliance with Standards

Check for relevant certifications such as UL, IEC, NEC, RoHS/REACH, and fire-resistance ratings (e.g., UL 444) to ensure safety, compatibility, and legal compliance.

6. Evaluate Mechanical & Electrical Performance

• Temperature range: PUR or TPE/TPU withstand wider ranges than PVC.
• Abrasion and strain resistance: Critical in dirty or high-wear environments.
• Electrical specs: Ensure adequate ampacity, voltage rating, and minimal voltage drop for your application.

Summary Table

By considering environment, jacket material, conductor design, shielding, standards, and performance, you ensure long-lasting and reliable industrial-grade flexible cables for harsh operating conditions.