Choosing the right industrial cables and wires is a major factor in optimizing electrical product design. While advanced technology and intricate layouts are important, the quality of the materials themselves can significantly impact performance.
With a vast array of options available, browsing a manufacturer’s e-store can be overwhelming. This cable selection guide offers valuable insights to help simplify your decision-making and find the best fit for your needs.
8 Cable Selection Guidelines
Following these eight electrical wire/cable guidelines will help you meet your unique requirements, down to the smallest detail:
- Mechanical durability
- Electrical performance
- Flexibility
- Heat, flame, & cold resistance
- Corrosion resistance
- Processability
- Price
- Availability
1. Mechanical Durability
Several elements of a wire assembly influence its strength, starting with its size and protective layers.
The gauge of an industrial cable refers to its thickness. Today’s customers are demanding smaller and smaller designs, which makes the physical side of cable performance a little harder to manage. A thinner cable is easier to sever or smash but there are ways to add protection:
Jacketing/
Insulation to Try
Armoring to Try
Conductor to Try
Filler
to Try
Crush resistance
Polyethylene, Neoprene, nylon, thermoplastic rubber
Steel
Steel
Steel
Cut-through resistance
Nylon, TPE,
fluoropolymers, XLPE
Steel
Nickel-plated
Polyimide tape
Avoid jacketing and insulation with weak mechanical properties if your cables are at risk of being stepped on, run over, or cut. Materials to stay away from include:
- PVC
- Thermoplastic rubber (for cut-through resistance)
- Paper (for filler)
2. Length
In a “normal” situation (no chemical fire, unexpected submerging, etc.), there are two main factors in a cable’s electrical performance: length and shielding.
Size requirements are different from at home, where “How long?” might be your only question. For the factory floor, there are entire electric cable guides dedicated to sizing best practices.
Gauge matters too, as thicker cables generally have lower resistance and can handle higher electrical loads across longer distances. Consider the current requirements of your application and select a gauge that can safely carry it without overheating or losing voltage.
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Length is still important too, but for more than just physical spacing of its connection points. A cable’s signal decreases as it travels, making excessively long cables a poor fit for applications that need low losses.
Oversized cable is also a waste of money, so only buy what you need. That said, if your assembly might change in location or expand in function later, include some slack and perhaps a service loop.
Shielding, meanwhile, is a feature dedicated specifically to preserving a cable’s ability to carry current.
Electromagnetic interference (EMI) is the enemy of electrical cabling, as it causes cross-talk (noise) and signal degradation. Shielding is a conductive layer that minimizes EMI by acting as a barrier. It may prove a more cost-effective design, as it helps you run farther with less cable before the signal degrades.
Take note of your project’s end-use location and whether nearby objects will play nicely with each other. If you’ve got 20 induction heating machines or automated conveyors in one room, dialing in a specific frequency will be challenging due to cable cross-talk. If you’re spec’ing cables for traffic signals, there’s no need for shielding because only air will surround them.
3. Flexibility
Your needs in this department are highly dependent on the cable’s intended use.
Benefits of a flexible industrial cable include:
- Fits in tighter spaces
- Less likely to snap
- Easier to use
Consider the flexibility requirements of your equipment, because not all connections need to or should be flexible.
A flexible cable would make sense for a robotic arm that rotates all day. A semi-rigid cable is easy to configure to your desired shape while maintaining its set, making it useful in metal-bending operations. A rigid cable is usually the top performer in high-power applications, like computer setups. They also cost less (usually), so it may be worth going that route if cable flexibility is irrelevant to your project.
A cable’s shielding (if any) is the biggest factor in its flexibility, with spiral shields the most flexible. Jacketing and insulation materials matter too, with thermoset and rubber types offering the most flexibility. Last and probably least important is the conductor type, of which stranded conductors are the most flexible.
Certain cables contain filler materials to improve flexibility:
- Cotton
- Aramid fiber
- Paper (note this is flexible, but has a short flex life)
4. Heat, Flame, & Cold Resistance
Some types of electrical wires and cables can endure high heat, some thrive in freezing temperatures, and a few excel at both. Meanwhile, some cables are popular because they don’t emit toxins while burning, while others are popular because they’re not flammable to begin with.
Choose cables with temperature ratings and fire reactivity appropriate for your application.
- High temperatures – A poorly rated cable will turn to mush, causing mechanical issues, conductor overheating, and insulation breakdown.
- Flames – UL rates cables for circuit integrity during a fire, as well as any smoke, toxic fumes, or corrosives produced when burning.
- Cold temperatures – Certain materials become brittle, lose flexibility, or otherwise degrade.
Cable jacketing and wire insulation choices are the #1 factor of success or failure relative to heat and cold:
Hazard
Good Examples
Bad Examples
Heat
????️
Silicone, fiberglass, PVDF,
FEP (Teflon), PFA
PVC, Neoprene, SBR
Flame
????
Thermoset materials, CEP (thermoplastic), FEP (Teflon), (PVDF), silicone
Polyethylene, PVC
Cold
❄️
Thermoplastic elastomer (Santoprene),
PTFE, EPR, PFA, silicone
PVC, polyurethane, polyethylene, rubber
“Highly resistant” is a relative term, so consult with your cable and wire distributor to best balance needs with budget. What’s “highly resistant” in an indoor appliance may not suffice for a military submarine.
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