1. Choosing the Wrong Cable Type for the Application

One of the most common reasons for cable failure is using a cable that is not designed for the working environment.

Different industrial applications require different cable structures:

• Drag chain applications require high-flex cables that can withstand millions of bending cycles.
• Servo motors need cables with excellent shielding performance to protect signal transmission.
• Robotic systems require cables designed for multi-axis movement and torsion resistance.
• Outdoor equipment requires cables with resistance against UV, moisture, and temperature changes.

For example, a standard PVC cable may work well in a fixed installation but can quickly fail when continuously moving inside a drag chain system.

Selecting the wrong cable type can lead to:

• Conductor breakage
• Insulation damage
• Signal interference
• Unexpected machine downtime

The correct cable design should always match the mechanical movement, electrical requirements, and environmental conditions.

2. Excessive Mechanical Stress and Continuous Bending

Industrial cables used in automation systems often experience constant movement.

Applications such as:

• CNC machines
• Robot arms
• Automated assembly lines
• Pick-and-place systems

require cables to bend, twist, and move thousands of times every day.

A cable without proper flexibility may develop internal damage even if the outer jacket looks normal.

Common mechanical failures include:

• Broken copper conductors
• Damaged insulation layers
• Shielding cracks
• Increased electrical resistance

High-flex cables and continuous-flex cables are specifically designed with special conductor structures, optimized insulation materials, and reinforced jackets to handle repeated movement.

3. Poor Cable Material Selection

The materials used in an industrial cable directly affect its service life.

Different environments require different jacket materials:

PVC Cable

PVC cables are cost-effective and suitable for many general applications.

PUR Cable

PUR (Polyurethane) cables offer excellent:

• Abrasion resistance
• Oil resistance
• Mechanical strength
• Flexibility

They are widely used in harsh industrial environments.

TPE Cable

TPE materials provide excellent flexibility and low-temperature performance.

Choosing an unsuitable material can cause:

• Jacket cracking
• Chemical damage
• Reduced flexibility
• Shortened cable lifespan

A high-quality cable starts with selecting the right materials for the actual working conditions.

4. Insufficient Shielding Against Electrical Interference

Modern factories contain many sources of electromagnetic interference (EMI), including:

• Servo drives
• Motors
• Inverters
• Welding equipment
• Power systems

Without proper shielding, cables may experience electromagnetic interference, causing:

• Signal errors
• Communication failures
• Unstable machine operation

For signal-sensitive applications such as servo systems and encoder systems, shielded cables are often essential.

A well-designed shielded cable helps maintain stable signal transmission and improves the reliability of automated equipment.

5. Overloading and Incorrect Electrical Design

Another major cause of cable failure is electrical stress.

Using a cable that cannot handle the required:

• Voltage
• Current
• Temperature
• Power load

can cause overheating and insulation deterioration.

Long-term overheating may result in:

• Insulation melting
• Short circuits
• Permanent cable damage

Before selecting a cable, engineers should carefully evaluate:

• Rated voltage
• Current capacity
• Installation environment
• Operating temperature

Proper electrical calculation can significantly reduce the risk of premature failure.

6. Poor Installation and Maintenance Practices

Even the highest-quality cable can fail if installed incorrectly.

Common installation mistakes include:

• Bending cables beyond the minimum bending radius
• Installing cables under excessive tension
• Incorrect drag chain filling rate
• Poor connector installation
• Lack of regular inspection

For moving cables, installation is especially important.

A cable inside a drag chain should have enough space to move freely. Overfilled cable chains can create additional pressure and accelerate wear.

Regular inspections can help identify early warning signs before complete failure occurs.

7. Using Low-Cost Cables Without Considering Long-Term Cost

Many companies choose cheaper cables to reduce initial purchasing costs.

However, the cheapest cable is not always the most economical solution.

A low-quality cable may result in:

• Frequent replacement
• Machine downtime
• Production delays
• Increased maintenance costs

For industrial automation systems, the total cost of ownership is often more important than the initial cable price.

A reliable cable may have a higher upfront cost but provide:

• Longer service life
• Higher machine availability
• Lower maintenance expenses
• Better production efficiency

In many cases, investing in a quality industrial cable can save significantly more money over the equipment lifecycle.

How to Prevent Industrial Cable Failure?

To improve cable reliability, companies should consider the following:

1. Select the correct cable for the application

Understand the requirements of your equipment, including:

• Movement type
• Bending frequency
• Temperature conditions
• Chemical exposure
• Electrical requirements

2. Choose a professional cable manufacturer

A reliable manufacturer can provide:

• Correct cable construction
• Suitable materials
• Customized solutions
• Technical support

3. Follow proper installation guidelines

Always check:

• Minimum bending radius
• Cable routing
• Drag chain compatibility
• Connector quality

4. Perform regular inspections

Early detection of cable wear can prevent unexpected production interruptions.

Looking for reliable industrial cable solutions?

 

AEIN Cable has over 14 years of experience in manufacturing:

• UL CMP Plenum Cable

• Servo Cable

• Drag Chain Cable

• Robot Cable

• Continuous Flex Cable

Visit http://www.aein-wirecable.com to explore our products and technical resources.