By Mark Froggatt, Head of Technical Training, Learning & Development, Eland Cables
Digital transformation is reshaping manufacturing. Connected machinery, real‑time monitoring, and data‑driven decision‑making are now essential to improving productivity and resilience. As systems become more interconnected and electrically complex, relatively small components can exert a significant influence on overall performance. Among them, the cables linking digital systems play a critical role.
When reliability issues arise in connected environments, attention often falls on visible digital elements such as sensors, drives, control platforms, or software. But in practice, many persistent problems originate lower down the system architecture. Cable selections made without sufficient consideration of electrical noise, mechanical demands, or operating conditions can quietly undermine stability and data quality. The symptoms are familiar: intermittent faults, drifting measurements, or unexplained downtime that takes time to diagnose.
One of the most important shifts accompanying digitalisation is the electrical environment inside modern facilities. Variable speed drives switch faster, increasing electromagnetic interference. Sensors and encoders generate higher‑resolution data at greater frequency, making signals more sensitive to noise. At the same time, space constraints push power, control, and data cables closer together and through tighter routing paths. In these conditions, cable behaviour has a direct impact on how reliably connected systems perform.
Mechanical suitability is a frequent blind spot. A cable that installs easily is not necessarily designed for continuous movement. In robotic cells, automated handling equipment and cable carrier systems, repeated bending, and torsion place specific demands on conductor construction and shielding design. When the cable does not match the application, fatigue can develop gradually, often leading to intermittent signal loss or communication errors long before visible damage appears.
Electromagnetic compatibility is equally influential. Connected manufacturing environments combine high‑power circuits with low‑level data and feedback signals. Without appropriate screening and correct termination, electrical noise can interfere with sensitive communications. Engineers may observe unstable readings or unpredictable device behaviour and assume the issue lies in software or calibration, when the underlying cause can often be traced back to cable performance.
Thermal and environmental factors add further complexity. Digitised systems frequently operate with variable loads or harmonics, creating fluctuating operating temperatures within cables. Even modest temperature increases raise conductor resistance and accelerate insulation ageing. Oils, cleaning agents, vibration, confined enclosures, and elevated ambient temperatures all influence long‑term cable life, making material selection an important design consideration.
As manufacturers progress toward smarter, more connected operations, cables should be viewed as part of the digital infrastructure rather than commodity components. They do not simply connect systems but influence power stability, data integrity and long‑term reliability. Giving cable specification proper attention at the design stage and drawing on application‑specific technical guidance where needed is a simple and effective way to protect uptime and maximise the value of digital transformation initiatives.
Related reading: Connected Worker Strategy
