Cable failure can halt operations and cause expensive downtime, which is why proper cable maintenance must be carried out to maximise lifespan and reliability. This can lead to huge cost savings later down the line.
In this blog, we will discuss factors that affect lifespan, common failures, and how to maximise lifespan.
Why Sensor Cable Maintenance Matters
Sensor cables operate in demanding environments and are therefore exposed to movement, heat, chemicals, moisture, and electrical stress. Over time, these factors can reduce performance and increase the risk of failure.
Without proper maintenance, you can expect:
- Small issues go unnoticed until they become major, costly faults.
- Signal integrity is breaking down and causing inaccurate readings.
- More equipment downtime.
- Frequent replacement of sensor cables increases costs.
It’s therefore important to create a proactive maintenance strategy to extend the cable’s lifespan, reduce unexpected failures, improve system reliability, and lower long-term operational costs.
What Impacts Sensor Cable Lifespan?
By understanding what causes sensor cable degradation, you can prevent it.
Mechanical Stress
Mechanical stress is the most common cause of sensor cable failure. This is due to:
- Repeated bending
- Twisting and torsion
- Pulling or tension during installation
- Vibration over time
These stresses can cause internal conductor breakage over time, even if the outer sheath looks intact.
Environmental Factors
Industrial environments like factories can be harsh, and sensor cables are frequently exposed to conditions that accelerate wear, including:
- Moisture – moisture causes corrosion, leads to insulation breakdown, and is dangerous in outdoor or washdown environments.
- Extreme temperatures – high heat can soften insulation and accelerate ageing, and cold temperatures can make them brittle and prone to cracking.
- UV exposure – UV light from the sun can degrade the outer sheathing, which eventually leads to cracking and loss of flexibility.
- Chemicals and oils – industrial fluids can break down cable jackets, which leads to swelling, cracking, or softening.
Electrical Stress
Electrical factors, such as exceeding voltage ratings, can cause overheating, leading to insulation failure and conductor damage. And electromagnetic interference can disrupt signal transmission and cause inaccurate readings.
Physical Damage
If sensor cables aren’t properly protected, they can be easily damaged by machinery, tools, and even foot traffic. Over time, abrasion can wear away the outer sheath, which exposes internal components and puts the cable at even more risk.
Insulation Breakdown
Insulation breakdown is a gradual process which may begin with slight discolouration or stiffness, but it will usually progress to cracking and eventual failure. Ensuring the environment in which the cable is working is free from chemicals, extreme temperatures, and UV light can reduce the risk of degradation.
Connector Failures
Connectors are a frequent point of failure as they are exposed and subject to movement. Therefore, issues can arise from poor insulation, environmental exposure, and mechanical stress.
Moisture Ingress
Water ingress can cause unpredictable behaviour, such as signal loss or even complete failure. These issues are usually inconsistent, which is complicated in terms of troubleshooting. Ensuring sheaths are intact can help reduce the risk of moisture-driven failures.
Tips to Maximise Sensor Cable Lifespan
Maximising cable lifespan needs a combination of preventive measures, proper handling, and ongoing monitoring. Here are some tips to help.
Establish a Structured Inspection Routine
Regular inspections allow businesses to identify any problems before they escalate. This includes both visual checks and, where appropriate, electrical testing. Visual checks focus on areas that experience the most stress, such as bends, cable entry points, and connection terminals, and electrical testing, like continuity of insulation resistance checks, provides a deeper level of insight where needed.
By doing this regularly over time, businesses can identify patterns and recurring issues.
Improving Installation Standards
The quality of installation has a direct impact on cable performance, as a lot of cable issues originate at the installation stage. For example, one of the most common problems is incorrect routing, where cables are installed too close to moving machinery or heat sources, subjecting them to continuous stress.
Therefore, to ensure cables are routed correctly, they should be secured in a way that prevents sagging and unnecessary movement, particularly near connectors.
Protecting Sensor Cables from Their Environment
Environmental protection is essential as most sensor cables operate in conditions that aren’t ideal. From dust and moisture to oil and chemicals, each element contributes to the gradual breakdown.
It’s therefore important to choose a sensor cable with specifications to match the environment. For example, UV-resistant jackets are essential for outdoor installations.
Managing Electrical Performance
Electrical performance plays a crucial role in reliability. Sensor cables are particularly sensitive because they frequently carry low-voltage signals that can be easily affected by external electrical conditions.
Proper grounding and shielding techniques should be used to help mitigate effects such as cable overload and electromagnetic interference (EMI). Shielded cables should always be used in high-interference environments, and cables should be routed separately from power cables where possible.
Maintaining Cleanliness and Storage
Cable maintenance doesn’t begin at installation; it actually starts at storage and handling. Cables that aren’t stored correctly can degrade way before they are even used. Elements like dust, oil, and chemical residue can slowly attack the outer sheath of a cable. It’s a gradual process that can reduce flexibility and weaken the protective outer layer. This means that once they are installed, the cable is more vulnerable.
Cables should be kept in dry, temperature-stable environments away from direct sunlight. They should also be properly coiled, as irregular coiling can introduce stress to the cable’s structure. By ensuring proper cleanliness and storage conditions, you can prevent premature ageing and reduce long-term strain.
A Practical Maintenance Checklist
To keep on top of your sensor cable maintenance, you should be carrying out weekly, monthly, quarterly, and annual checks.
- Weekly – quick weekly visual inspections and connection checks are fast, non-intrusive, and focused on identifying obvious signs of issues. This could include displacement, unexpected tension, loose routing, and areas where cables are rubbing against machinery.
- Monthly – monthly maintenance is a deeper level of inspection, focusing on gradual environmental and mechanical effects. Cleaning should be a part of this stage, as cables in industrial environments are usually exposed to dust, oil mist, or coolant residue.
- Quarterly – quarterly maintenance focuses on performance and integrity. The goal at this stage is to identify hidden or developing faults that are not yet visible externally. This is also a good stage to identify trends, such as if multiple cables in a specific area show similar wear patterns, it could indicate an issue, such as poor routine design.
- Annually, annual maintenance requires a high level of inspection, with a focus shift from individual cable condition to overall system reliability and future planning. A full system audit should review every aspect of cable performance.
Looking for the Right Sensor Cable for Your Application?
Selecting the correct cable is one of the most important factors in maximising lifespan and reliability. If you’re unsure which specification best suits your environment, our team is here to help.
Get in touch with K Lacey Cables for expert guidance and tailored solutions designed to perform in even the most demanding conditions.