Control cables act as the nervous system of machinery and automation. They carry signals that start, stop, and regulate movement in everything from production lines to defense systems. A custom control cable, designed to fit your exact needs, can dramatically improve both reliability and cost efficiency.
Why Customization Matters
Off-the-shelf cables work for general tasks, but complex environments demand precision. Factors like electrical noise, space constraints, and temperature exposure can all dictate performance.
Typical Customizations Include:
- Conductor Count & Gauge: Tailored to signal and power requirements.
- Insulation Type: PVC for cost-effective protection; XLPE or Teflon for higher temperatures.
- Shielding Configuration: Braid, foil, or combination shielding to combat EMI/RFI.
- Color Coding: Simplifies wiring and maintenance.
- Outer Jacket Material: Determines abrasion and chemical resistance.
Benefits of Custom Control Cables
- Improved System Performance – Minimize noise and signal delay.
- Reduced Downtime – Longer life under repeated flexing and vibration.
- Simplified Installation – Built to exact lengths and connector types.
- Regulatory Compliance – Designed to meet UL, CSA, or MIL-SPEC standards.
Applications
Custom control cables are used in robotics, factory automation, aerospace, power generation, and any field where environmental or performance constraints exist.
Common Mistakes in Cable Specification
- Ignoring Mechanical Stress: Repeated bending without proper flex rating shortens life.
- Overlooking Shielding Needs: Noise interference can cripple sensitive control systems.
- Skipping Documentation: Failing to request specs and traceability can cause compliance issues.
The Imperial Approach
With nearly five decades in wire and cable distribution, Imperial Wire & Cable partners with trusted manufacturers to ensure every custom order meets exact requirements—on time, within spec, and with the documentation needed for audit or defense projects.
Key Takeaway
Custom cables are not a luxury—they’re a performance investment. By designing cables to your specifications, you achieve smoother operations, longer component life, and higher system efficiency.