Why Control Cables Are Essential in Industrial Setups

Why Control Cables Are Essential in Industrial Setups

Behind every reliable machine lies a system of control cables that keeps everything connected and functioning smoothly. These cables help machines, sensors, and PLCs communicate in real time, which improves efficiency and reduces downtime due to error or malfunction. They also ensure that electrical signals move as quickly and accurately as possible so that industrial settings can run continuously without disruption. This article takes a closer look at what control cables are, how they work, and why they're essential in industrial setups throughout the UK.

What is a control cable?

The purpose of a control cable is to carry low voltage signals between machines, sensors, and PLCs in an industrial setup. Unlike power cables that transfer electrical energy, control cables send instructions and signals for smooth machine operation. These signals can include signals to start, stop, and adjust speed. They can also be used to monitor systems, detect issues, and send feedback to machines for better performance. Control cables are an integral part of any industrial automation system, and they are available in various sizes to meet the specific needs of a given application.

In most cases, control cables are designed for indoor applications and can be found in industrial environments like factories and power plants. They are built to withstand exposure to heat, moisture, and vibration for long-lasting reliability. They are also constructed for safety and feature a flame retardant outer layer to keep the conductors safe in case of fire.

Often, shielded control cables are preferred to unshielded options because they feature an extra layer of protection. This added layer prevents electromagnetic interference from disrupting the signal inside the cable, which can be a serious problem in highly-complex systems. This type of cable is also designed for flexibility, allowing it to easily bend and flex to accommodate the needs of dynamic applications such as conveyor belts and machine tool axes.

A control cable's size is typically determined by its voltage class and conductor cross-section. For instance, a 7x19 aircraft control cable has seven wires and 19 strands of metal, which allows it to be used at a maximum of 600V / 1000V. In contrast, a motor cable is only required to be operated at 300V / 500V and requires a smaller conductor size.

In addition to voltage class, another key difference between control cables and motor cables is the number of wires that each contains. While a motor cable only requires four wires, control cables are more likely to have multiple wires in order to handle the various functions of an industrial system. This makes them a common choice for complex machinery and industrial automation rigs. Note that it's important to maintain proper separation between cables with different voltage classes in the same cable tray. For example, never bundle a control cable that uses 120V solenoid power with an instrumentation cable that sends 4-20mA signals; this could cause a current overload and pose a risk of fire.

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