Choosing the right material

What is the best material for a cable sheath – PUR or PVC? Is stainless steel a better material for connector housings than cast zinc or plastic? These questions can only be answered on a case-by-case basis, as each material has its own strengths and weaknesses. Unfortunately, there are no simple rules when it comes to choosing the right materials for connectivity solutions, as the specific application always plays a decisive role. Furthermore, any connection solution is only ever as strong as its weakest link. This is often an unsuitable material or accessory where the manufacturer did not pay enough attention to material properties for seemingly unimportant C-parts.

Requirements can vary greatly from one sector to another. In the food and beverage industry, for example, hygiene is the number-one priority when processing and packaging perishable goods. This calls for materials that can be easily washed down and that do not lose their functionality when they are treated with hot steam and aggressive cleaning agents. The rail industry, on the other hand, requires cables that can be safely routed inside passenger carriages. Here, they must meet strict fire protection standards. As you can see, the demands on the cables are completely different, calling for different materials to be used. These differences are also reflected in connectors, cable glands, seals and other accessories.

To find out where exactly these differences lie in the cables, we need to look at the most important cable components, starting from inside at the conductor and insulator and then working outwards to the sheath. The conductor is often made from bare copper, although tin- or silver-plated conductors can be a more sensible choice depending on the application and environmental influences. Tin plating protects the copper against a type of corrosion called tarnishing, helping to preserve its high conductivity. Silver-plated conductors offer the same advantage, and are often used in high-temperature applications.

The insulation – Not just for protecting against short circuits

Conductors require electrical insulation. In single-core wires, this insulation acts as touch protection. In multi-core wires, it prevents current flowing from one conductor to another and causing a short circuit. You may have already experienced what happens when this insulation fails. When putting away old hair dryers or irons, for example, we often wrap the power cord around the handle. After being wrapped and twisted like this thousands of times, the sheath breaks followed by the insulation, usually at the point where the cable enters the housing. A flash of electricity then shoots out of the cable and the lights in the house go out with a loud bang after the fuse hopefully trips. If unsuitable cables are used in industrial applications, not only can these incidents happen more frequently, but the consequences can be severe, such as hours of production downtime in a factory.

Insulation must do more than just provide protection, however. In data transfer cables like ETHERLINE®, the insulation can determine the transmission quality or, more precisely, the signal losses during transmission. This is because the electrical signal interacts with the plastic and gives off energy. This causes the plastic to heat up slightly and the signal weakens until it causes dropouts. The most important factor here is the dielectric constant of the plastic, which should be as low as possible. Polyethylene and polypropylene are plastics that offer a low dielectric constant. This value can be reduced further by using nitrogen to turn the plastic into a foam when it is extruded onto the conductor. Lapp subsidiary CEAM Cavi Speciali, based in the Italian town of Monselice, produces its high-quality data cables in a complex process. Here, up to three layers are applied simultaneously from three extruders, while the middle layer is foamed. These cables enable high data transfer rates across long distances, and are also slightly thinner than conventional cables. This is because the foam layer offers better insulation properties, and can therefore be thinner.

Fire protection – Beware halogens

The behaviour in case of a fire is another important aspect for cables. Flame-retardant insulation material is required wherever there is a risk of fire, in order to meet the fire protection classes of the European Construction Products Regulation (CPR). The easiest way to achieve good fire protection is by mixing the plastic with substances containing halogens. These are elements of the seventh group in the periodic table, often brominated compounds. This fire protection strategy is highly efficient as it requires few additives, thus maintaining the mechanical properties of the material. These cables are therefore often used by car manufacturers in the engine compartment. In public areas like buses, however, halogen has a major disadvantage. In the event of a fire, halogen creates noxious smoke that mixes with extinguishing water to form corrosive vapours.

HFFR plastics (halogen free flame retardant) are a non-toxic alternative, but they require a filling level of sometimes over 60 percent, which can significantly affect the mechanical properties of the plastic. One new trend is the use of so-called synergistic systems. These combine two substances that together provide better flame protection than either individual material would alone. One possible combination is halogen-free aluminium trihydrate and silane compounds. When it comes into contact with fire, aluminium trihydrate reacts to form aluminium oxide and water. This endothermic reaction draws energy from the fire. A crust of combusted material also forms and acts as a protective barrier.

Another factor to bear in mind is that flame retardants are hydrophilic, meaning they have the unwanted characteristic of attracting water. In a worst-case scenario, this can cause an electric breakdown. This is not a problem for cables that do not come into contact with water. But in some sectors like the food industry, where hot water is used for cleaning, different materials are needed. Flame retardants coated with silane compounds are more suitable here. These make the plastic hydrophobic, i.e. water repellent.

Cable sheath – Armed against the elements

The sheath is subject to even tougher demands than the insulation, as it is directly exposed to environmental influences. It must withstand abrasion, chemicals, cleaning agents, UV light, temperature and much more. Unfortunately, there is no one material that meets all requirements. The material must be tailored precisely to the respective purpose. Depending on the application, cables must withstand lubrication oil, greases and cleaning agents to name just a few. The mechanical engineering sector uses tried-and-tested cables with sheaths made from polyvinyl chloride or polyurethane (PUR). PUR is the workhorse of sheath materials. It offers some of the strongest chemical bonds available. It is difficult to process, however, when producing both the cable and assemblies, as the sheath does not cut easily. PUR is also flammable and expensive. The cable types ÖLFLEX® 408P and ÖLFLEX® 409P find a compromise that combines the toughness of PUR with the easy processing of PVC. These cables feature a PUR outer sheath and a interstice filler functional layer made from PVC.

Cables used outdoors are exposed to the sun, and require a different combination of materials. In this case, the sheath must contain UV stabilisers. In solar cables (such as ÖLFLEX® SOLAR), soot is added to the mix to block sunlight, hence the fact that these cables are usually black. The ideal solution for outdoor cables is radiation crosslinking. Here, the cable is bombarded with electron beams. The plastic molecules absorb the energy from the electrons and become interlaced, making the material much more resistant. This allows the cables to withstand extreme temperature swings from minus 40 to 120 degrees Celsius, as well as high mechanical loads. This mechanical resistance is also the reason why crosslinking is also used for cables in the rail industry, such as ÖLFLEX® TRAIN. Several materials are suitable for crosslinking, including polyethylene (PE), polyolefin elastomers (POE), ethylene vinyl acetate (EVA) or ethylene ethyl acrylate (EEA). Additives are generally also added in crosslinking, usually around one percent, in order to improve the bonds between the molecule chains. They also reduce the amount of energy required in the crosslinking process.

Unlike unlinked material, which eventually softens, crosslinked material has no melting point. When heated, it oxidises and becomes brittle, which makes it necessary to add antioxidants and stabilisers. Crosslinking offers no advantage at very low temperatures, as the material will inevitably become brittle at some point. This makes it all the more important to select a base polymer that is suitable for low temperatures. Possible materials include polyolefin elastomers (POE), linear low-density polyethylene (LLDPE), certain kinds of ethylene vinyl acetate copolymers (EVA) or thermoplastic elastomers (TPE). If the application calls for tougher mechanical properties, suitable materials include high-density polyethylene (HDPE) or polypropylene (PP, for greater strength), as well as polyolefin elastomers (for greater elasticity).

Cables for the foodstuffs industry – The battle against bacteria

In the foodstuffs industry, the top priority is resistance against biological influences like microbes and fungi. In cheese factories, the bacteria that help the cheese ripen can corrode a conventional cable in a matter of months, leading to short circuits. Sheath materials made from special TPE, such as those used on Lapp’s ROBUST cables, repel bacteria and are easy to clean. The secret of Lapp’s special thermoplastic elastomer is the smooth surface. This is achieved with a smart mixture of additives that fill microscopic gaps in the material and that stay bonded in the plastic matrix even after heavy cleaning with a steam jet. The combination of strong substances with flexible polymer chains in between gives the mixture rubber-like properties, while being as easy to process as thermoplastics. Some suppliers offer PUR cables for use in the foodstuffs industry that offer extremely high mechanical strength. But PUR is hydrophilic, meaning that it attracts water. Special TPE, by contrast, is hydrophobic.

All of these mixtures, however, are powerless against larger lifeforms like rodents. That is why underground cables are protected with flavourings like vanillin or are specially reinforced. Alongside steel reinforcement, other materials are available that splinter when bitten and spoil the hungry animals’ appetite. When it comes to the devastation that martens can cause, certain materials that do not take on odours may provide a solution. Scientists believe that the reason why martens attack cables has to do with battles over territory. Martens mark their territory with their droppings, urine and sweat from glands in their paws. Their rivals try to destroy these markings. A cable that does not take on odours cannot be marked and is therefore not attacked.

Rust-free connections – Stainless steel the material of choice

From the cable to the gland to the connector, from plastic to metal. Here, the answer seems clear: stainless steel is the material of choice when connector housings or cable and hose glands need to withstand chemicals or cleaning agents. In the foodstuffs industry, stainless steel is often essential. It does not rust and there is no coating that could eventually flake off. But the situation is not as easy as it appears, as there are different types of stainless steel. Conventional V2A stainless steel is relatively low-cost but is often not sufficiently robust when it comes to chemical resistance. Stains can appear on the metal when it is immersed in substances containing chlorides. The foodstuffs industry often uses hypochlorous acid that disintegrates into hydrochloric acid and kills organic substances. V2A stainless steel is not suitable here. V4A stainless steel offers a tougher alloy and is also used on expensive Swiss watches. It is extremely hard and withstands impacts and cleaning with coarse brushes.

As ever in life, however, for every advantage there is a disadvantage. Stainless steel is harder than brass or standard steel, and is therefore more difficult to process. This is especially true of V4A due to the alloy elements chromium, nickel and molybdenum. If its surface is left untreated, V4A is rougher, leading to higher abrasion. Screws that have to withstand high forces across their thread would therefore be stuck. This is why Lapp gives its products made from V4A stainless steel (such as the EHEDG-certified SKINTOP® HYGIENIC cable gland) a special surface treatment that reduces abrasion and makes it easy to tighten and release the cable gland.

Stainless steel cannot be used everywhere. One example of this is in rectangular connectors. Stainless steel is unsuitable here because the metal is too hard to be processed. The connector would have to be milled from a complete block, which would be far too expensive for customers. Lapp therefore found a different solution for its EPIC® ULTRA. The housing on this rectangular connector is made from nickel-plated cast zinc. This material resists corrosion, such as from salt spray on oil platforms or in the foodstuffs industry. For bolts and brackets, however, Lapp recommends using stainless steel. This is because any coating would be quickly worn off by the frequent opening and closing when separating the modules, such as during cleaning. Cast-on bolts are not suitable here, as the clamping forces and therefore the tightness reduces over time due to the low stability of the material, whether plastic or cast aluminium.

But bolts and brackets pose a dilemma for the foodstuffs industry. These components contradict the principles of hygienic design, as the nooks and corners can trap splashes from food processing. Other locking methods are either not secure enough or are not compatible with the market standard. Lapp therefore recommends not using such connectors in the product zone, but rather only in areas that do not come into direct contact with food.

Some companies use plastic housings that offer some resistance against acids and alkaline solutions. But plastic housings present the risk of low dimensional stability under mechanical or environmental influences. This can also lead to leaks, presenting a safety risk. There is a risk of accidents and high follow-up costs for maintenance and service. Plastic is also unsuitable for applications in which electromagnetic compatibility is important. At the very least, they must be coated with metal to protect against interference. In practice, the results in terms of screening are often disappointing.

Sealing – Rubber vs. silicon

Wherever metal meets metal, such as a connector and a control cabinet, there is usually a seal sitting in between. It must have similar temperature and media resistance characteristics to the materials that make up the other components in the connector or gland, otherwise it will become the weak link in the chain. Fluorocarbon elastomers (FKM) are the best solution here, but are expensive. These resist the effects of weather, ageing, ozone and chemicals, and withstand temperatures of up to 200 degrees Celsius. In moderate ambient conditions, ethylene propylene diene monome rubber (EPDM) is a good alternative. FKM does have one small disadvantage. It is not suitable for very cold environments, and should not be used at temperatures under -20 degrees Celsius. Silicon is a better choice for refrigerated warehouses or other very cold or hot environments. On the other hand, it is not suitable for use at very high temperatures such as in furnaces. Just as important as the seal’s material is its design. Seals used in food processing should not have any gaps or crevices where residues could settle. The seals of the SKINTOP® HYGIENIC range, for example, adjust to the shape of the sealed surfaces and join flush without creating any gaps.

For users, finding the right products is not always easy. Many order stainless steel components just to be on the safe side, without knowing the media with which the connectors will come into contact. Alternatively, users dial back their requirements and use improved standard products for their cables and connectors, in the knowledge that these will often need replacing. There is no one right answer here, the best way to proceed is to weigh up the various advantages and disadvantages. The experts at Lapp know their products extremely well. Users should always consult them before potentially making the wrong choice.

 

The future with Fiber Optic cables

Internet penetration in India is a major concern and will be for a while. Only 400 million of India’s 1.2 billion strong population is online, after all. As fiber optic technology continues to revolutionize the telecommunication and data capabilities of a range of industries, the average individual may not understand the advantages that fiber optic technology provides for us in our everyday life. To better understand the advantages and capabilities of fiber optic technology, we’ll outline a few basics touch points of fiber optics and their contribution to our everyday lives. Let us catch up on the benefits of optical fiber over traditional metallic wire.

Benefits of Optic Fibers Vs. Traditional Metallic Wiring?

Besides the fact that conventional metallic wiring is far more expensive to produce, fiber optics deliver a superior amount of quality, convenience, and durability currently unmatched in telecommunication technology. Although the majority of our practical applications in the past used metallic wiring, fiber optics technology is rapidly growing and seems likely to stay for generations to come.

We’ve included a few advantages that optic fibers have over metallic wiring below:

Digital signalling: Optical fibers are suited naturally to accommodate digital information, a dominant form of data that we use for computer networks.

Optimized Capacity:  Copper or metal wires are very thick, and are unable to be as portable or flexible as fiber optic wires due to the fiber’s hair-like thinness. This allows fiber optic wires to optimize carrying capacity, allowing more channels to be available in any given area.

Signal Integrity: Losing signal is far less common with fiber optics. Especially considering the majority of transmitted data is digital. The core of the optic fiber cable is made of glass, rendering the signal immune against electrometric interference, crosstalk, impedance issues, and more.

Affordable: The production of optical cables are less expensive than the production of copper wire. When considering the advantages and capabilities of fiber optics in comparison to metallic wiring, the affordability increases the value of usage over copper wire immensely.

Light Signaling: Where metallic wiring utilizes analog, electrical signals, optic fibers utilize light. This means that one fiber does not interfere with another fiber within the same wire, allowing for a clearer signal during phone calls or while using the internet.

Flexibility: The usage of fiber optic technology is highly adaptable to many industries. Telecommunications and computer networking specifically, which utilize fiber optics to maintain performance, are used frequently as essential parts of modern living. Optic fiber cables are also immune to environmental damage, protecting them against temperature fluctuations that could otherwise damage metallic wires. In addition, optic fiber wires can be submerged in water, allowing them to reach destinations otherwise impossible for copper cables.

Increased Safety: Optic fiber cables do not use electricity, and therefore there is no chance of sparking or fire hazards.

In Conclusion

In today’s world, many businesses and individuals rely on a dependable and proficient connection to perform their daily tasks. Fiber optic technology delivers service on a level of quality that commercial organizations and industries recognize. In fact, the majority of these industry leaders have moved onto fiber optic technology as it continues to make its way throughout all areas of telecommunication.

The expansion of fiber optics within internet services, television, streaming media, network gaming, social media, and more, has made a profound impact in what both individuals and organizations have the ability to do. Fiber optic technology will continue to offer many more opportunities to provide users with affordable, more convenient, and higher quality data communication. Do check LAPP, cable manufacturers in India if you have the requirement of quality fiber optic cables.

Common Fiber Optic Cables Problems

As Clint Eastwood quoted, “Aging can be fun if you lay back and enjoy it.” However this quote does not apply to the fiber optic cables or any cable in general.

Some fiber optic networks have now been in use for more than 20 years, a tribute to the inherent capabilities of optical fiber. In that same time, copper cabling for premises networks has been through two generations of coax and at least four generations of unshielded twisted pair cabling.

Why do the Old Fiber Optic Cables still Works so Well?

• One reason is the extreme care that went into its design. Telephone cable engineers already knew how to make cable that would survive for long times buried underground or suspended from poles. Adapting that technology to glass fibers, while adding plastics to protect the fiber from the environment by hermetically sealing the glass, and using the then new technology of aramid fibers to prevent stress on the glass itself, led to the creation of fiber optic cables that have lifetimes well over the 20 years of current use.

 

• Another factor in the lifetime of fiber is that it needs no maintenance. Connectors are effectively sealed from dirt in patch panels, and splices are sealed in enclosures that prevent moisture from entering. There is no need to disconnect terminations to clean, inspect or test them.

If we focus on the problems encountered by fiber optic cable as listed below. This information will help you be better equipped to prevent and even rectify any problems should they arise.

External Damage

A thorough visual inspection of the fiber optic cable will be sufficient to highlight any prominent defects that have affected the casing or the conductors. It doesn’t take a significant amount of damage to affect the ability of the cable to work properly. It is prudent to replace the cable if any issues become apparent from the inspection, such as splits or scratches.

Too Long

A fiber optic cable that has excess length after a connection has been made will at risk of bending, twisting or winding around itself. These actions can result in permanent damage to the fibers and components within the cable. Cables are available in a range of different lengths and you should ensure that you get the correct one with the use of a measuring tape. Position all the equipment that you intend to connect with the cable measure the distance between them to get an idea of the approximate length. There are some varieties that contain a rod to prevent it being bent and these can be used to prevent a recurrence of the same problem.

Stretching

The components within a fiber optic cable are delicate and can be damaged if stretched across a distance that it cannot comfortably accommodate. Avoid the risk of the fibers within the cable becoming damaged by moving the items closer together or obtaining a cable of a more appropriate length. Stretching can also occur from pulling at the jacket of the cable rather than using the grips at the connectors designed to be used to fit and remove them. Always use the grips to remove the connector from the socket that holds it.

Connectors

Performance problems can occur in the event that the connectors of the fiber optic cable are not fitted properly. Check each of the connectors to determine whether this is the case and rectify it by inserting them properly. If the problem continues to occur, replace the cable with a version that makes use of spring loaded connectors that fit securely without slipping out of place.

Fibers

Where the fibers within the cable are broken or damaged in some way, this will not be immediately evident when simply considering it with the naked eye. In order to check this, a fiber optic tracer can be utilized to highlight any faults within the cable. This implement resembles a miniature flashlight that uses an LED and can be fitted to the cable connector for the purpose of checking continuity. If the fibers are all intact and working correctly, the light that is shone at one of the cable should be visible at the other end of the cable.

This information will help you be prepared for the unexpected situation. LAPP, cable manufacturers in India, provides quality tested cables, which reduces the problems which you may encounter.

 

How to deal with outdoor cables?

 

As the saying goes, “Accidents, big or small, avoid them all you.” Special care needs to be taken around electricity outdoors. Whether you are working or playing near it, or using electrical equipment, it is important to be aware of the dangers. Everything we use around us works on electric current, it is very much necessary to maintain safety guidelines.

Before you start any work near power lines or underground cables, arrange a visit from electricity retailer to identify any problems or disconnect the supply. This work might be painting your house, trimming trees, cleaning guttering, replacing spouting or roofing, repairing chimneys or excavating a property.

Never touch overhead power lines, underground cables, or the bare conductors that connect them to the house, as this could be fatal.

Safety tips for Outdoors

• Never store material under power wires and reduce the clearance height. Remember that children are fond of climbing, and wires look tempting.
• Before starting work on a roof, make sure no aerial lines pass overhead. If they do, arrange with your electricity retailer to have them protected, or isolated before starting work.
• A power line that has fallen to the ground should be treated as live, contact your electricity supplier immediately. Do not touch the line, and warn your family members and neighbors.

Safe clearances

Safe clearances between building work and power lines minimize the risk of electric shock, fire, power cuts, or damage to property and power lines.

The minimum safe clearance between power lines and buildings depends on the voltage of the power line and the type of conductor. Types of power lines can usually be recognized by their construction and by the type of insulator or number of disc insulators which separate the power line from the power pole or tower.

You can browse through the LAPP, cable manufacturers in India for protective cables. Prior to any planned construction, a process for establishing safe distances from power lines must be undertaken to comply with this code of practice.

You must check with your electricity supplier to find out what the power line voltage is so you can establish the right clearance.

Using electrical tools and equipment outside

Take special precautions when you use electrical appliances outdoors or in a damp environment. Electrical equipment and appliances used outside include electric lawn mowers, weed eaters, water blasters, and power tools.

• Never use any damaged appliances or equipment with damaged leads outdoors. Visually check the cords for any cuts or damage to the cord, and run your hand down its length to feel for cracks or damage. If you find a problem, don’t use the equipment until the cord is professionally repaired or replaced.
• Never use them in rainy or wet conditions.
• Always use a residual current device (RCD) or an isolating transformer. These protect you from a fatal electric shock by cutting the current if there is an electrical problem.
• Keep children and pets a safe distance away when you operate a mower or any other electrical equipment.
• Wear strong protective footwear when working with electrical appliances or tools outside, do not work in jandals or bare feet.

Keep cords and electrical equipment away from any metal that can catch or cut it, for example, metal ladders, garage workbenches, metal roofs and garden fences. Mentioned guidelines would help you avoid any possible accidents.

Safety measures while dealing with Underground cables

This blog focuses on approach while dealing with underground cables, which is often overlooked. It can be harmful and hazardous if not dealt right.

One of the main dangers which may arise when digging is that of possible injury from underground power cables. Injuries resulting from damage to live power cables are usually caused by the explosive effects of arcing current and by associated fire or flames. This can occur when the sheath of the cable and the conductor insulation are penetrated by a sharp object, such as the point of a tool, or when the cable is crushed severely enough to cause contact between the sheathing and one or more conductors.

This typically causes severe and potentially fatal burns to the hands, face and body.

Direct electric shock is also a possibility. Furthermore, some high voltage power cables are oil filled and oil can ignite. Electrical fires can be catastrophic if damage spreads to other nearby services such as gas pipes. Such accidents are caused by failure to take all reasonably practicable precautions to prevent accidental contact with underground services.

Recommended methods and procedures, which, if adopted, will provide a positive approach to the elimination of these tragedies.

The basic elements of a safe system of work involve:

1.Correct use of Plans (to aid location of power cables)

Before starting work it is essential that you have all of the cable records for the location and that these are kept on site at all times while work is proceeding. Make sure that they are up-to-date; that they cover all cable voltages at the location; that you understand how to interpret them; and that they are fully utilised both in advance of commencing digging and throughout the full duration of the work.

2.Use of Cable Locating Devices

Suitable cable locating devices should be used in conjunction with the cable plans to determine as accurately as possible the position of underground cables in or near the proposed work area.

3.Use of Safe Digging Practice

These three key elements complement each other and all three should be used when working near buried services.

LAPP, one of the leading cable manufacturers in India, provides cable based on the application. Therefore, you will find wide range of the cables, these cables are tested under extreme circumstances. Therefore, you can rely on the quality and be sure that you would be safe. Do visit the official website of LAPP to check the available options of the cables.

 

 

 

Guidelines for Robotic cable management

To improve the efficiency of any system, you need to have certain structure. In this blog, we are going to focus on Robotic cable management, is a fundamental part of robotic efficiency, often overlooked or saved for the last part of the design process.

There are several special considerations that need to take place to ensure proper robotic cable management. If you still have questions such as, why is robotic cable management important? How can you ensure you choose the best robotic cable management solution?

The Importance

Poor management of robotic cables can lead to a number of problems. The most common is the poorly designed cable system which restricts the motion of a robotic arm. With robots becoming more flexible, we need upgrade in the cable design to match this flexibility. By preparing cables for the entire range of motion of the robot, not just application specific motions. You would not want to end up with a cable that restricts the motion, and thus the flexibility and efficiency, of the robotic arm.

Even tightly binding cables with excessive dress packs creates problems like corkscrewing. To reduce any sort of unproductive and unscheduled downtime, it is better to avoid any stress on robotic cables which accelerates their lifetime and increases the chance of failure.

Best Practices

What are the things which you can do to optimize robotic cable management? One of the most important ones is to consider six-axis robots in three different segments: the sixth axis to the third axis, the third axis to the second axis, and the second axis to the first axis. This allows maximum control over cable design and can reduce the amount of cable management equipment needed. With better control, and less strain on the cables, ensures better life for the cables.

You do not have to dismantle the entire system once the cables exceed their service life, you can replace them. The robotic cable carrier system is of great use for robotic cable management. Robotic cable carriers have spring-loaded designs to minimize catch and pinch points.

For good robotic cable management, you’ll also want to make sure all cables are in one continuous path with no pinching or loose cables around any of the axes. It’s also helpful to have the option to fully enclose cables to protect them from harsh environments, although permanently enclosed systems have their drawbacks.

Proper robotic cable management can be achieved many different ways, depending on the needs of your specific application. The tips mentioned above are some of the best ways to ensure your robotic cables aren’t hindering robotic performance.

Robotic cable management is especially important in robotic welding applications where robotic efficiency and ROI is found through excellent uptime. Check Lapp, cable manufacturers in India, for the applications which would require quality robotic cables.

 

Basics of Cables and Connectors

If we check the history of electric cables, the real demand for wires and Cables to conduct electric power began in 1871, with the invention of the first dependable dynamo.

The telegraph and telephone swelled demand for efficient methods of transmitting electric current and signals over long distances. The insulation back in the days was paper coated. Just imagine Paper-coated pitch wrapped each individual wire, insulating it from the others. The whole batch was then wrapped in paper. Some even suggested laying these batches in tubes coated in resin and placing them underground to keep curious young boys away from them.

In the case of cables, factors like resistance, capacitance and impedance all play a role. There’s also a great many more electrical sources, magnetic sources and broadcast radio frequencies today than there were in the days of paper and pitch insulation. All of these factors can affect a cable’s transmission. As a result, shielding is another important variable in audio and video cabling. Let’s check out the basic terminology which is used when we consider the transfer of electric current.

Electrons, Voltage and Current

Electrons, and therefore electric charges, move through conductors. If they didn’t, the world today would be a very different place. A flow of electrons (a charge) flows from a voltage or signal source (like a battery) through two conductive surfaces (that is, materials that allow electrons to pass through them).

Hook a wire to two ends of a battery and you’ve got flow. This movement of electrons has many characteristics. The two of interest at the moment are voltage and current. Voltage is like the “pressure” created by the flow of electrons. Current is the rate of the resulting flow.

Resistance is the quality of a material that restricts the free flow of electrons. As a conductor resists the flow of current through it, a small percentage of the energy dissipates.

Metal wires are good conductors and resist little of the current that runs through them, though there is some loss. They also have a large surface to volume ratio. This is crucial because, oddly enough, electrons travel over the surface of the wire and not through the middle.

Capacitance is the tendency of a material to store energy and block constant or low-frequency currents. Capacitors filter and store energy, among other things. Different conductors have different resistive and/or capacitive properties. A shielded cable has similar properties to a capacitor, as both consists of two conductors separated by some type of insulator.

Capacitance is a factor in cable design because it reacts with the impedance in a length of wire to strip away high frequencies. In the video, that means a loss of detail; in audio, a loss of clarity. In cables, the lower the capacitance, the better.

Shielding

There’s a lot of electrical and magnetic interference in the air these days. Other power sources, appliances, close proximity to radio or TV stations-all these and more can create noise picked up by your cable unless properly shielded.

A shield is another conductive material, normally a metal foil or a wire mesh, that encircles and protects the integrity of your cable. It absorbs outside signals and/or reflects them back to the outside world. It also keeps your signal within your cable. The relationship between the conductor and shield within your cable can increase the Cable’s capacitance. Once again, careful design is everything.

Impedance

Audio and video signals are alternating current signals. They’re similar to waves, like sine waves. For a wave to pass cleanly across a cable from one component to another, the impedance-or signal opposition-must be equal all the way across. The cable must be rated to carry signal at a certain impedance.

If the impedances do not match between signal source, cable and receiving component, the waves get out of phase and collide with each other. This actually reflects some of the power of the signal back to the source, causing noise and signal loss.

The more reflection, the less clean your signal, ultimately leading to loss of picture or color data. The video signal is a high-frequency one, very susceptible to problems with impedance.

The Coaxial Cable

You’ve no doubt heard the term coaxial-coax for short-throw about. Fancy word, simple concept: coax simply refers to any cable with a central wire surrounded by an insulator, a shield and a plastic outer jacket. if you’ve seen almost any kind of AV cable other than cheap speaker wire, you’ve seen the coaxial cable.

In this article, we have checked the terminology related to cables and connectors. Do check out LAPP, one of the leading cable manufacturers in India, to purchase the best quality cables and connectors.

 

Basics with LAPP, Connector Manufacturers India

To reduce any instances of the short circuit, we make use of connectors. And, LAPP, Connector Manufacturers India is doing a great job in providing quality connectors to ensure safety.

The electrical accidents are lethal, LAPP, Connector Manufacturers India, is well equipped to handle this sort of incidents. Most of the short circuit incidences can be avoided just by making use of quality connectors.

What are connectors and how are they employed?

The basic requirement while using any system is the safe conduct of electric current. We have insulated cables to ensure the transfer of electricity, in order to establish the continuous path we make use of electric connectors.

In this section, our focus will be on the terminology and specifications associated with connectors. The different connector types as well as the basic formats and the different types of specification.

• Plugs and sockets: There are two formats of connectors, one being the male, or plug, and the other is the female section, that is the socket. The female connector can supply power.  The male section has pins, as they are exposed they are never used to supply power, which would involve risk of short circuit. The contacts in the female connector are more protected and therefore it is safer to have power on them while there is no mating connection.

 

• Number of pins: Determining the number of pins required helps in calculating the actual conductor parts, including the series of connectors to be used. When choosing a particular connector it is standard practice to ensure there are a few spare pins for any future unforeseen requirements.

 

• Number of insertions:Life of the conductors are specified in terms of the mating cycles, which is the process of connection and disconnection. While the conductors have a definite life cycle, which means they are going to wear out over time.  Based on the specification and the usage select the connector.

 

• Mechanical considerations: We need to consider the physical size and shape and the environment into consideration. There are a number of mechanical considerations when choosing connectors. Physical size and shape is an important factor, but there may also be environmental requirements. Will it operate over a given temperature range, or withstand moisture. These and other mechanical aspects need to be considered when choosing the type of connector.

 

• Current capacity: Some connectors carry high current while some carry low. It is preferred for the connectors to have high current handling capability, as most connectors can take a few milliamps without a problem. Ensure using good quality connectors with high current capability for safety purposes.

 

• Voltage capacity: It is not safe to operate the connector after the certain voltage. While virtually all connectors will be suitable for low voltages when they rise to what may be termed hazardous voltages, care needs to be taken as insulation may fail, or there may be flashover. Accordingly, it is always worth ensuring that the maximum voltage is not exceeded. Specifications may be provided for AC and DC.

 

The choice of the connector can play an important part in the design of any equipment. This blog should give you a brief on the things you need to look out for while selecting the connector. Check LAPP, Connector Manufacturers India for more details.

History of Data Communication cables

The by-products of the advancing technology has certainly created a lot of confusion among the consumers. If we consider the networking cables, the types of network cables employed in any network infrastructure is one of the most important aspects of networking, and it has become increasingly critical with the introduction of newer technologies.

If we go through the history of the data communication cables, you will find the roots from where it all started.

History

We tend to think of digital communication as a new idea, if we go back in time, like in 1844, Samuel Morse sent a message 37 miles from Washington, D.C. to Baltimore, using his new invention, the telegraph. This may seem a far cry from today’s computer networks, but the principles remain the same.

Morse code is a type of binary system that uses dots and dashes in different sequences to represent letters and numbers. Modern data networks use ones and zeros to achieve the same result. The big difference is, while the telegraph operators of the mid-19th century could perhaps transmit four or five dots and dashes per second, computers now communicate at speeds of up to 10 Gbps or, to put it another way, 10,000,000,000 separate ones and zeros every second.

Although the telegraph and the teletypewriter were the forerunners of data communications, it has only been in the last 35 years that things have really started to speed up. This was borne out of the necessity for computers to communicate at ever-increasing speeds, which has driven the development of faster and faster networking equipment. In the process, higher-specification cables and connecting hardware were required.

Let us shed some light on the most popular data communication cable:

Unshielded twisted pair (UTP)

UTP cable is used not only for networking but also for the traditional telephone (UTP-CAT1). There are six different types of UTP categories and, depending on what you want to achieve, you would need the appropriate type of network cable. UTP-CAT5e is the most popular UTP cable; it replaced the old coaxial cable that was unable to keep up with the constantly growing need for faster and more reliable networks.

Characteristics of UTP categories

The characteristics of UTP are very good and make it easy to work with, install, expand and troubleshoot.

So, let’s have a quick look at each of the UTP categories available today:

These categories specify the type of copper wire — most telephone and network wire is copper and jacks.

CAT1 is typically used for telephone wire. This type of wire is not capable of supporting computer network traffic and is not twisted. CAT1 is also used by telco companies providing Integrated Services Digital Network and public switched telephone network services. In such cases, the wiring between the customer’s site and the telco’s network is performed using CAT1-type cable.

CAT2, CAT3, CAT4, CAT5/5e, CAT6, and CAT7 are network wire specifications. These types of wires can support computer network and telephone traffic. CAT2 is used mostly for token ring networks and supports speeds up to 4 Mbps. For higher network speeds,100 Mbps or higher, CAT5e must be used. For the almost-extinct 10 Mbps speed requirements, CAT3 will suffice.

CAT3, CAT4 and CAT5 cables are four pairs of twisted copper wires; CAT5 has more twists per inch than CAT3. Therefore, CAT5 can run at higher speeds and greater lengths. The twist effect of each pair of the cables ensures any interference presented or picked up on one cable is canceled by the cable’s partner that twists around the initial cable. CAT3 and CAT4 are both used for token ring networks, where CAT3 can provide support of a maximum 10 Mbps, while CAT4 pushed the limit up to 16 Mbps. Both categories have a limit of 100 meters.

CAT6 wire was originally designed to support Gigabit Ethernet, although there are standards that will allow gigabit transmission over CAT5e wire. It is similar to CAT5e wire, but contains a physical separator between the four pairs to further reduce electromagnetic interference. CAT6 is able to support speeds of 1 Gbps for lengths of up to 100 meters, and 10 Gbps is also supported for lengths of up to 55 meters.

CAT7 is a newer copper cable specification designed to support speeds of 10 Gbps at lengths of up to 100 meters. To achieve this, the cable features four individually shielded pairs, plus an additional cable shield to protect the signals from crosstalk and electromagnetic interference.

Briefly, we visited the major data communication cables in use. Do go through Lapp, one of the leading cable manufacturers in India, to get the right cable for your application.

Common household electrical problems

Not many have the superpower to see the subtle signs of electrical problems, which can cause catastrophic effect, if not taken care of. When it comes to household electrics, your safety is paramount. Cable manufacturers in India such as LAPP is constantly working towards building safer environment to control electricity, without causing any harm.

Talking about signs, flickering lights, high bills and damaged appliances can all be a sign of electrical problems on your home circuit. In this article, we are going to shift our focus to identifying problems, with the appropriate solution, which is listed below.

1.Frequent electrical surges

Electrical surges can be caused by anything from lightning strikes, damage to power lines, faulty appliances and bad electrical wiring in the house. While an actual surge only lasts a microsecond, frequent surges can damage the electrical components connected to your home, degrading their life expectancy significantly.

If you experience frequent electrical surges, the culprit is probably an electrical device connected to the home grid or the wiring itself. Try removing any cheaply made devices or power boards from the outlet to see if this prevents the surges. Otherwise, it might be time to consult a professional electrician.

2.Sags and dips in power

Like electrical surges, sags and dips in electrical supply can often be attributed to devices connected to your power grid that are faulty or made with substandard materials, and draw a lot of power when they are turned on

3.Light switches not working properly

Dimmer switches that don’t adjust light properly can often be attributed to shoddy workmanship or sub-standard products.

If you have just moved into a new house and find switches that don’t seem to activate anything at all, this might be a sign the switches have been superseded and fixtures removed, or it could be a fault in the outlet, circuit or wiring. Consult with an electrician if you’re experiencing issues with switches in your house.

4.Circuit Breaker tripping frequently

High wattage items like microwaves and hairdryers can trip circuit breakers, particularly when other power consuming items are used on the same source. A circuit breaker is designed to protect you and your home, so when it does a trip, that’s a sign it’s doing its job.

Look at what you were using when it tripped. If it was a hair dryer, try using the low setting. Alternatively, limit the electrical usage on a single circuit while high watt devices are in use.

5.Circuit Overload

One of the biggest causes of frequent circuit breaker tripping is the overloading of power boards. Most homes and apartments, even newer ones, don’t have enough power points to cater to, for example, a complete home entertainment unit setup. If circuit breakers in your home are tripping frequently, it could be down to circuit overload.

Prevent this by:

• Never daisy-chain power boards.
• Remove devices that aren’t in use (for example, phone chargers still draw power even when not connected).
• Spread your electrical needs around. Don’t overburden a single circuit.
• Be mindful of how you connect devices around the home – what’s in use, and what is unnecessary.

6.Lights too bright or dim

If some lights around the house seem excessively bright but others are dim, then there are two probable causes:

• Different types of lights with different wattage: Check that all the globes are identical.
• Bad main neutral connection: This will continue to cause problems for the home until it is fixed by a professional.

7.Electrical Shocks

An electrical shock is a nasty experience. Even though they are usually pretty mild, something akin to a static shock, they remind us that electricity is dangerous when not probably utilized.

Electrical shocks typically happen when you turn a device on or off. The issue could be with the appliance, or it could be in the wiring. You can test this by plugging in another device and seeing if the results are reproducible, however, you’re just risking another electrical shock. In most cases, it might be better to speak with an electrician.

8.High Electrical bill

Reducing the cost of your electrical bill could include:

• Switching to a more cost-effective provider
• Identifying electrical devices that may be causing power surges
• Patching leaks in the hot water system
• Unplugging appliances and chargers when not in use
• Repairing damaged wiring or circuits

 

WHAT TO DO IF PROBLEMS PERSIST

If electrical problems are ongoing around your home, you should consider contacting an electrician. Safety around the home is paramount, so don’t leave anything to change.

Use the top notch electrical equipment, from LAPP, cable manufacturers in India, who have the tested products to ensure your safety.