Industrial Cable Assemblies factory

How to compare the flexibility of different industrial cable types

In industrial settings, the flexibility of cables directly impacts installation efficiency, operational reliability, and service life—especially in applications like robotics, automated production lines, and movable machinery. However, comparing cable flexibility is not a subjective assessment; it requires a systematic analysis of key technical characteristics and performance metrics. This article outlines actionable methods to evaluate and compare the flexibility of different industrial cable types, helping engineers and procurement professionals make informed decisions.

1. Key Factors for Comparing Cable Flexibility

1.1 Conductor Construction

The conductor is the foundation of a cable’s flexibility. Two critical aspects to examine are strand count and stranding pattern. Cables with more fine strands (e.g., 19-strand or 37-strand copper conductors) are significantly more flexible than those with fewer, thicker strands (e.g., 7-strand). For example, a 37-strand 16 AWG conductor can bend repeatedly without fatigue, while a 7-strand conductor of the same gauge may crack after limited flexing. Additionally, class 5 or class 6 flexible conductors (per IEC 60228) are designed for dynamic flexing, whereas class 1 or 2 conductors are rigid and suited for fixed installations. When comparing, always check the conductor’s stranding class and strand diameter—smaller, more numerous strands indicate better flexibility.

1.2 Insulation & Sheath Materials

The material of the insulation (around conductors) and sheath (outer layer) plays a pivotal role in flexibility. Rigid materials like PVC (polyvinyl chloride) may become brittle at low temperatures, reducing flexibility, while elastomeric materials offer superior pliability. Common flexible materials include: TPU (Thermoplastic Polyurethane): Resists oil, abrasion, and temperature extremes (-40°C to 80°C), maintaining flexibility in harsh environments.PUR (Polyurethane): Offers excellent dynamic flex life, ideal for cables in continuous motion (e.g., robotic arms).Silicone Rubber: Remains flexible at ultra-low temperatures (-60°C) and high heat (180°C), suitable for extreme-temperature applications. To compare, test flexibility under the intended operating temperature range—materials that harden or crack at operational temps are less suitable, even if flexible at room temperature.

1.3 Cable Core Design

The arrangement of conductors, fillers, and shielding within the cable core affects flexibility. Cables with twisted conductor pairs or bunched cores distribute stress more evenly during bending, compared to those with parallel conductors or rigid fillers (e.g., plastic rods). Shielding also matters: braided shields (e.g., tinned copper braid) are more flexible than spiral shields, as they conform to bending without kinking. Avoid cables with thick, inflexible armor (e.g., steel tape) if dynamic flexibility is required—opt for lightweight, flexible shielding like aluminum mylar tape with drain wires instead.

1.4 Bending Radius Specifications

The minimum bending radius (MBR) is a quantifiable metric that defines the smallest circle a cable can bend around without damage. It is typically specified as a multiple of the cable’s outer diameter (OD), e.g., 6×OD for static bending and 10×OD for dynamic bending. A lower MBR indicates better flexibility. For example, a cable with an MBR of 5×OD can bend tighter than one with 8×OD. Always compare MBR values under the same conditions (static vs. dynamic) — dynamic MBR is more critical for applications involving repeated movement.

1.5 Environmental Adaptability

Flexibility can degrade under environmental stress, so evaluate performance in the target application’s conditions: Temperature: Low temperatures can make materials brittle (e.g., PVC), while high temps may soften them (e.g., some rubbers). Test flexibility at the application’s min/max temps.Chemicals/Oil: Exposure to oils or solvents can swell or harden sheaths—PUR/TPU cables resist this better than PVC.Abrasion: Flexible cables in high-wear areas need durable sheaths to maintain flexibility over time; check abrasion resistance ratings (e.g., ISO 6722).

2. A Step-by-Step Comparison Framework

1. Define Application Requirements: Note dynamic vs. static use, bending frequency, temperature range, and environmental hazards (oil, abrasion).
2. Gather Technical Datasheets: Extract conductor stranding, insulation/sheath material, MBR, and flex life (e.g., number of bending cycles before failure).
3. Conduct Practical Tests: For critical applications, perform bend tests: secure the cable and repeat bending to the MBR, checking for conductor breakage or sheath cracking.
4. Rank by Weighted Criteria: Assign weights to factors (e.g., 40% dynamic MBR, 30% flex life, 30% environmental resistance) and score each cable type.

3. FRS Brand: Flexible Cables for Industrial Excellence

When flexibility and reliability matter most, FRS brand industrial cables stand out. Engineered with high-strand class 6 conductors, oil-resistant PUR sheaths, and optimized core designs, FRS cables deliver exceptional dynamic flexibility—with MBR as low as 4×OD and flex life exceeding 10 million cycles. Whether for robotic arms, conveyor systems, or extreme-temperature environments, FRS cables maintain consistent performance where rigid alternatives fail. Backed by strict quality control and customization options, FRS is the trusted choice for factories seeking flexible, durable cable solutions that reduce downtime and boost productivity. Choose FRS—flexibility designed for industry.