Industrial Cable Assemblies factory

Why is industrial cable thickness important for performance

In industrial settings—from manufacturing plants to power distribution systems—cables are the backbone of operations. While factors like material quality and insulation type matter, cable thickness (measured by cross-sectional area, often in AWG or mm²) is a non-negotiable factor that directly dictates performance, reliability, and safety. Below is a breakdown of its critical roles, supported by real-world industrial needs:

1. Current-Carrying Capacity: Avoid Overheating and Downtime

The primary function of many industrial cables is to transmit electrical current to power machinery, motors, or control systems. Thickness directly impacts a cable’s ability to handle current without overheating, a principle rooted in Joule’s Law (heat generated = I²Rt, where R = resistance).

• Thicker cables have a larger cross-sectional area, which reduces electrical resistance. Lower resistance means less heat buildup when current flows—critical for high-power applications like heavy-duty motors or welding equipment. For example, a 10AWG (5.26 mm²) copper cable can safely carry ~30 amps in continuous use, while a thinner 16AWG (1.31 mm²) cable maxes out at ~13 amps. Using a 16AWG cable for a 20-amp motor would cause excessive heat, melting insulation, tripping breakers, or even starting fires.
• In industrial environments where downtime costs thousands per hour, undersized (too-thin) cables lead to unplanned shutdowns. Overheating also degrades cable materials over time, shortening lifespan and increasing maintenance costs.

2. Signal Integrity: Ensure Precision in Automation and Sensing

For data-transmitting cables (e.g., Ethernet cables for factory automation, sensor cables for IoT devices), thickness directly affects signal quality—especially in high-frequency or long-distance applications.

• Thicker conductors minimize signal attenuation (signal loss over distance). In automated assembly lines, for instance, a thin 24AWG cable transmitting sensor data 50 meters may suffer 20% signal loss, causing misreads of pressure or temperature sensors. A thicker 20AWG cable, by contrast, reduces loss to under 5%, ensuring machinery responds accurately to real-time data.
• Thickness also stabilizes impedance (a measure of signal resistance). Industrial control systems (e.g., PLCs) require consistent impedance to avoid signal reflection or interference. A cable with inconsistent thickness (e.g., a 18AWG core with uneven diameter) creates impedance spikes, leading to communication errors between robots and control panels.

3. Mechanical Durability: Withstand Industrial Wear and Tear

Industrial cables face extreme mechanical stress: constant bending (in robotic arms), abrasion (against conveyor belts), and impact (from heavy tools). Thickness—especially in the cable’s insulation and jacket—determines how well it resists damage.

• A thicker jacket (e.g., 2mm vs. 0.8mm) acts as a buffer against physical harm. In mining operations, for example, cables with thin jackets often tear when dragged over rough rock, exposing conductors and causing short circuits. Thicker jackets (made of durable materials like PVC or TPU) extend cable life by 2–3x in such harsh conditions.
• Thicker conductors also resist fatigue from repeated bending. In packaging machinery with moving parts, a thin 22AWG cable may break after 1,000 bending cycles, while a 18AWG cable lasts 5,000+ cycles—reducing the need for frequent replacements.

4. Environmental Resistance: Protect Against Harsh Conditions

Industrial environments expose cables to chemicals, moisture, extreme temperatures, and UV radiation. Thickness plays a key role in enhancing environmental resilience.

• Thicker insulation layers provide a stronger barrier against corrosive substances (e.g., oils in automotive factories, solvents in chemical plants). A 1.5mm-thick chemical-resistant insulation layer can prevent fluid penetration for 5+ years, while a 0.5mm layer may fail in 6 months—leading to conductor corrosion and system failures.
• In high-temperature settings (e.g., steel mills, where temperatures reach 150°C), thicker insulation (combined with heat-resistant materials like PTFE) slows heat transfer to the conductor, maintaining performance. Thin insulation may harden and crack at high temps, breaking the circuit.

5. Safety and Compliance: Meet Industrial Standards

Every industry has strict safety standards (e.g., IEC 60228 for conductor size, NEC Article 310 for current ratings) that mandate minimum cable thickness. Non-compliant (too-thin) cables pose severe risks:

• In explosive environments (e.g., oil refineries), thin cables may overheat and spark, igniting flammable vapors. Standards like IEC 60079 require thick enough conductors to limit heat and thick insulation to prevent spark leakage.
• In commercial buildings with industrial equipment, thin cables violate fire safety codes—they burn faster and release toxic fumes, endangering workers. Compliant thickness ensures cables meet fire-resistance ratings (e.g., VW-1) and reduce fire spread.

Conclusion

Industrial cable thickness is not a “one-size-fits-all” specification—it is a performance-critical choice tailored to application needs. Whether you’re transmitting high current, precise data, or protecting against harsh conditions, undersized cables lead to downtime, safety hazards, and higher costs. Investing in cables with the right thickness ensures long-term reliability and efficiency.

At FRS, we recognize that industrial cable thickness is the foundation of consistent performance. Our factory designs and manufactures cables engineered for your specific needs: from thick-gauge cables for heavy machinery (ensuring maximum current-carrying capacity) to precision-thin cables for automation (guaranteeing signal integrity). Every FRS cable adheres to global standards (IEC, NEC) and uses high-grade materials—ensuring optimal thickness, durability, and safety. Trust FRS to keep your industrial operations running smoothly, with cables that minimize downtime and stand the test of harsh environments.