An industrial cable assembly typically consists of the following parts:
1. Conductor (Core)
Function: Transmits electrical current or signals.
Materials: High-conductivity metals like copper or aluminum; optical fibers for signal transmission in specific applications.
Design: Cross-sectional shapes include round, sector-shaped, or segmented configurations.
2. Insulation Layer
Function: Electrically isolates the conductor to prevent leakage or short circuits.
Materials: PVC (polyvinyl chloride), XLPE (cross-linked polyethylene), rubber, or other polymers.
3. Shielding Layer
Function: Blocks electromagnetic interference (EMI) and improves signal integrity.
Materials: Aluminum foil, metal braiding (e.g., copper or tinned copper).
Applications: Critical for high-voltage cables or environments with strong EMI (e.g., industrial automation, data transmission).
4. Inner Sheath (Protective Layer)
Function: Mechanically protects the insulation layer from damage and chemical corrosion.
Materials: Lead, aluminum, or polymer-based materials.
5. Filling and Armor Layers
Filling Layer: Fills gaps between cores for structural stability; made of fiber or rubber.
Armor Layer: Provides enhanced mechanical protection (e.g., crush resistance, tensile strength).
Materials: Steel tape, galvanized steel wire.
Applications: Underground installations or harsh environments.
6. Outer Sheath (Jacket)
Function: Protects against environmental factors (moisture, heat, abrasion).
Materials: PVC, PE (polyethylene), or rubber compounds.
Structural Summary
Component Function & Materials Typical Applications
Conductor Current/signal transmission; copper, aluminum, or fiber optics. Power grids, communication systems.
Insulation Layer Electrical isolation; PVC, XLPE, rubber. All cable types.
Shielding Layer EMI suppression; aluminum foil, metal braiding. High-voltage systems, precision sensors.
Armor Layer Mechanical reinforcement; steel tape/wire. Underground, high-stress environments.
Outer Sheath Environmental protection; PVC, PE, rubber. Outdoor, chemical, or humid conditions.
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