Flexible cables rise to meet the demands of modern automation

In today’s industrial landscape, the demands on electrical and data cabling have changed dramatically. Manufacturing plants, warehouses, and automated facilities rely heavily on equipment that moves, bends, and twists during operation. As automation and robotics become increasingly prevalent, the need for flexible cables capable of withstanding continuous movement has grown significantly.

Flexible cables differ from standard fixed installations in their construction and performance characteristics. Unlike traditional wiring, which is primarily designed for static use, flexible cables are engineered to endure repeated bending, torsion, and mechanical stress over long periods. This makes them essential for a range of applications, from robotic arms and conveyor systems to drag chains and automated guided vehicles.

Flexible cables are not just a convenience — they are a critical aspect of operational reliability.

Applications across industries

Industries such as automotive manufacturing, packaging, food and beverage processing, and energy production rely on flexible cabling to ensure equipment operates safely and efficiently. In a modern production line, cables are no longer just passive connections; they are critical components that must maintain electrical integrity under constant motion.

For example, a robotic arm in an automotive assembly plant may perform hundreds of movements per minute. The cables supplying power and transmitting signals must endure millions of bending cycles without failure. Similarly, in energy sectors like wind power, fibre optic cables experience torsion as turbine blades rotate, demanding materials that can tolerate extreme stress and environmental exposure.

The consequence of using inadequate cables is significant. Cable failures can lead to production downtime, costly repairs, and in some cases, safety risks for personnel. Flexible cables are therefore not just a convenience — they are a critical aspect of operational reliability.

Types of motion in cables

The stresses placed on cables in dynamic environments are not all the same. Depending on the application, cables may face different forms of mechanical load:

• Bending: The cable is continuously flexed back and forth, sometimes millions of times, such as in drag chains or conveyor systems.
• Torsion: The cable is twisted lengthways. Pure torsional movements are most common in wind turbines, where cables run from the rotating nacelle down into the tower. More often, however, applications involve both bending and twisting simultaneously.
• Rewinding and unwinding: Common in event technology or live television broadcasting, where cables are repeatedly unrolled from drums, then rolled back up and stored after use.
   

Understanding these mechanical stresses is essential for selecting the right cable for each task.

Categories of flexible cables

Flexible cables are available in a range of types, each tailored to specific industrial requirements:

• Power and Control Cables: For motors, actuators, and sensors requiring reliable energy and control signal delivery.
• Data Cables: Designed for low-frequency signal and control transmission in industrial environments. Ideal for process control, sensors, and communication between devices.
• Ethernet and Network Cables: High-speed cables for reliable data transmission in industrial Ethernet networks, including flexible and moving applications such as cable chains and robotic systems.
• Fibre Optic Cables: High-performance cables for fast, interference-free communication across long distances, built to withstand bending and torsion in dynamic industrial applications.

What sets robot cables apart

Not all flexible cables are created equal. Special robot cables differ in many ways from other robust cables for moving applications. The most important difference is that robot cables can withstand both bending and torsion over their entire service life. They are fundamentally designed differently during development compared with a drag chain cable.

Three parameters are especially important when engineering robot cables:

• Stranded conductor class: Robot cables exposed to torsional loads often use “fine-stranded” Class 5 strands. Highly flexible cables used in pure bending applications, such as energy chains, may use Class 6 strands. However, even Class 6 is not always sufficient for the highest demands. Some manufacturers use ultra-fine wires — with diameters as small as 0.05 mm — outside the standard to achieve the required flexibility.
• Torsion angle: Expressed in degrees per metre of cable length. A typical value is 360°/m, meaning a cable can be twisted once around its axis per metre without damage. Shielded cables usually tolerate only half this, at around 180°/m.
• Bending radius: Ideally between 4 and 7.5 times the cable’s outer diameter, allowing routing in tight radii and dense hose packages without compromising durability.
   

By considering these parameters, engineers can ensure that cables perform reliably over years of demanding use.

Engineering for longevity

The design of flexible cables incorporates features that enhance durability and service life. Conductors are stranded or finely braided for greater flexibility, while jacketing materials are chosen for resistance to abrasion, oils, heat, and UV exposure. Many cables are tested to simulate millions of bending and torsion cycles, ensuring they can withstand real-world demands.

In addition, modular design and standardisation are becoming more common, making cable replacement and system upgrades faster and less disruptive. This approach supports uptime and helps extend the service life of industrial equipment.

Sustainability considerations

As in many areas of manufacturing, sustainability is an important factor. Longer-lasting cables reduce the frequency of replacements, thereby decreasing material consumption and waste. Some manufacturers are incorporating recyclable materials and optimising production processes to lower the carbon footprint of their operations.

By combining durability with environmental responsibility, the industry is finding ways to support both operational efficiency and sustainability goals.

Meeting the demands of modern industry

As automation, robotics, and smart manufacturing continue to transform operations, the role of flexible cables is becoming increasingly critical. They are no longer an afterthought but a core component of industrial reliability.

For engineers and facility managers, the key is understanding the specific stresses involved in each application and selecting cables designed to withstand them. When this is done correctly, flexible cables can help minimise downtime, reduce costs, and ensure safe, reliable operation.

In this way, flexible cabling is not just a connector — it is a vital enabler of modern industrial performance.