WBCFLEX-SDQJ circular cable

WBCFLEX-SDQJ circular cableIt is a high flexibility special cable designed specifically for dynamic applications such as robots, automation equipment, drag chain systems, etc. Its electrical performance needs to be comprehensively analyzed based on its structural characteristics (such as conductor material, insulation material, shielding method, sheath type, etc.). The following provides a systematic analysis of its electrical performance from the perspectives of core electrical parameters, the impact of structure on performance, typical application scenarios, and key points for selection and maintenance:

1、 Core electrical performance parameters

2、 The influence of structure on electrical performance

1. Conductor design

• tinned copper wire：

• Strong antioxidant properties, suitable for humid or corrosive environments (such as food processing equipment).

• The fine twisted structure (such as 0.08mm single wire diameter) enhances flexibility and reduces the risk of bending fatigue fracture.

• Bare copper conductor：

• Lower cost, slightly better conductivity (without coating resistance), but long-term exposure to humid environments should be avoided.

• Selection of cross-sectional area：

• Determine based on load current and voltage drop requirements (such as 2.5mm ² copper conductor can carry approximately 28A current, with a 20% margin reserved for dynamic applications).

2. Insulation materials

• TPE (thermoplastic elastomer)：

• Temperature resistance range: -40 ℃ to+105 ℃, excellent flexibility (bending radius ≤ 5 × D).

• Dielectric constant ≈ 2.8, low capacitance, suitable for high-frequency signal transmission (such as servo motor encoder).

• The wear resistance is average and needs to be used in conjunction with a protective sheath.

• PUR (polyurethane)：

• Temperature resistance range: -40 ℃ to+90 ℃, wear-resistant, oil resistant, and chemically resistant (such as industrial lubricants).

• The dielectric constant is approximately 3.5, and the capacitance is slightly higher. It is necessary to optimize the conductor spacing to reduce signal distortion.

• Flame retardancy can be improved by adding flame retardants (such as those that comply with UL 94 V-0).

• silicone rubber：

• Temperature resistance range: -60 ℃ to+180 ℃, flexibility (suitable for extremely low temperature environments).

• The dielectric constant is approximately 3.2, the capacitance is moderate, but the cost is high, and it is mostly used in applications such as aerospace.

3. Shielding layer design

• Copper wire braided shielding：

• Shielding density ≥ 85% (high frequency ≥ 95%), balancing flexibility and shielding effectiveness.

• Suitable for dynamic bending scenarios (such as robotic arms), but it is important to note that the grounding resistance should be ≤ 0.1 Ω.

• Copper tape wrapped shielding：

• The shielding coverage rate is 99.99%, with high shielding effectiveness (≥ 80dB), but poor flexibility, suitable for static installation (such as wiring inside control cabinets).

• Aluminum foil+copper wire braided double-layer shielding：

• Aluminum foil provides 99.99% coverage and copper wire weaving enhances high-frequency shielding, making it suitable for strong interference environments such as frequency converter output terminals.

4. Sheath material

• PUR sheath：

• Excellent wear resistance (DIN 53516 test ≥ 500000 times), suitable for high friction scenarios (such as drag chain systems).

• Oil resistance meets the EN 60811-404 standard and can be in long-term contact with mineral oil.

• TPE sheath：

• Flexibility (bending radius ≤ 4 × D), suitable for dynamic applications with compact space (such as medical equipment joints).

• Poor weather resistance, long-term exposure to ultraviolet radiation should be avoided (UV stabilizers can be added to improve).

• LSZH (low smoke halogen-free) sheath：

• No halogen emissions during combustion, low smoke density (compliant with IEC 61034), suitable for public buildings such as subways and airports.

• The temperature resistance is average (70 ℃ to 90 ℃), and the cost is relatively high.

3、 Typical application scenarios and electrical performance requirements

1. Industrial robots

• demandHigh frequency motion, anti electromagnetic interference, and oil resistance.

• WBCFLEX-SDQJ configuration：

• Conductor: Tin plated fine twisted copper wire (0.08mm single wire diameter).

• Insulation: TPE (temperature resistance -40 ℃ to+105 ℃).

• Shielding: Copper wire weaving (density ≥ 95%)+aluminum foil double-layer shielding.

• Sheath: PUR (wear-resistant, oil resistant).

• performance advantage：

• Shielding efficiency ≥ 60dB (10MHz), reducing motor driver interference.

• Bending life ≥ 15 million times (radius 5 × D), suitable for high-frequency motion of robot joints.

2. Servo control system

• demandLow capacitance, low noise, high-speed signal transmission.

• WBCFLEX-SDQJ configuration：

• Conductor: Bare copper fine twisted wire (0.05mm single wire diameter).

• Insulation: Low capacitance TPE (dielectric constant ≤ 2.5).

• Shielding: Copper tape wrapping (99.99% coverage)+copper wire braided grounding.

• Sheath: TPE (with good flexibility).

• performance advantage：

• Capacitor ≤ 0.08 μ F/km to reduce encoder signal distortion.

• Transmission rate ≥ 10Mbps (compliant with CANopen and EtherCAT protocol requirements).

3. New energy charging equipment

• demandUV resistant, weather resistant, low smoke and halogen-free.

• WBCFLEX-SDQJ configuration：

• Conductor: Tin plated copper wire (corrosion-resistant).

• Insulation: XLPE (temperature resistance of 90 ℃, high dielectric strength).

• Shielding: Copper wire weaving (density ≥ 85%).

• Sheath: LSZH (flame retardant, low smoke).

• performance advantage：

• Compliant with IEC 62893-4-2 standard (for charging cables only).

• Smoke density ≤ 50 (GB/T 17651), meeting the fire protection requirements for outdoor charging stations.

4. Medical equipment

• demandBiocompatibility, low toxicity, flexibility.

• WBCFLEX-SDQJ configuration：

• Conductor: Silver plated copper wire (low resistance, anti-oxidation).

• Insulation: TPE grade (compliant with ISO 10993 biocompatibility).

• Shielding: Copper wire weaving (density ≥ 90%).

• Sheath: TPE (non-toxic, good flexibility).

• performance advantage：

• Can be sterilized (such as ETO, gamma rays).

• Suitable for precision equipment such as endoscopes and surgical robots.

4、 Selection and maintenance points

1. Selection principles

• Temperature matching：

• Choose XLPE or silicone rubber insulation for long-term high temperature environments (>85 ℃), and TPE or silicone rubber sheath for low temperature environments (<-15 ℃).

• Mechanical demand：

• High frequency bending: Select fine twisted copper wire+PUR sheath (bending radius ≤ 5 × D).

• Direct burial laying: choose steel belt armor+anti rodent and ant outer sheath (if supported by the model).

• electromagnetic environment：

• Strong interference scenarios (such as frequency converter output): Double layer shielding (aluminum foil+copper wire weaving) must be used.

• Multi signal transmission: Select phase shielded cables to reduce crosstalk.

• Fire prevention requirements：

• Public buildings: Choose LSZH sheath+flame retardant (if compliant with GB/T 19666).

• Explosion hazardous area: Choose explosion-proof type (such as ATEX certification).

2. Maintenance and testing

• regular testing：

• Insulation resistance testUsing a 500V megohmmeter, it is recommended to use ≥ 1M Ω/km.

• Continuity test of shielding layerEnsure that the shielding layer has no open circuits or poor contacts (grounding resistance ≤ 0.1 Ω).

• Visual inspectionCheck whether the sheath is cracked, worn, or deformed (especially pay attention to the bent parts).

• Fault handling：

• If the insulation resistance decreases or the shielding layer fails, the cable needs to be replaced immediately.

• Avoid long-term exposure of cables to high temperatures or chemically corrosive environments (such as PUR sheaths that are not resistant to strong acids).

• Installation precautions：

• Bending radius ≥ 5 × D (dynamic application) or ≥ 8 × D (static application).

• Avoid cable twisting or excessive stretching (tensile force ≤ 20N/mm ²).

5、 Comparison with similar products

summary

WBCFLEX-SDQJ circular cableBy optimizing the conductor structure, insulation material, shielding layer, and sheath design, high flexibility, long lifespan, and anti-interference characteristics have been achieved, making it particularly suitable for dynamic application scenarios such as industrial robots, servo systems, and new energy charging. When selecting, special attention should be paid to temperature, mechanical stress, electromagnetic environment, and fire protection requirements, and regular testing and maintenance should be carried out to ensure stable performance.