Connectivity in Welding Environments

PrintWhen working in harsh environments and in heavy duty applications like welding, it is important to take a multi-angle approach to designing the application. When you are working with existing sensor installations, it is important to consider all the reasons for the sensor’s failure before determining a winning solution. An important step in any application is to protect the connection between the controller and the sensor. In a welding environment, whether the sensor cable fails from weld slag buildup or from physical damage from contact with a part, the cable can be the key to a successful weld-sensing application.

siliconecables
Silicone Cable vs Silicone Jacket Cable

That being said, the number of options available to protect the connection can be overwhelming and at times even confusing. For example, silicone cables vs silicone tube cables. Silicone cables have a jacket that is made out of silicone material over the conductors.  This usually allows for a smaller diameter and more variety with the cordsets i.e. length and connector types. On the other hand, a silicone tube cable is a standard sensor cable with a silicone pulled over the cable then over-molded.  The silicone tube is a second jacket and the air is a good insulator, prolonging the life of the sensor cable.

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Sensor with Connector vs Sensor with Cable Out

Another important consideration is how to even connect your sensor. One option is to install a sensor with a connector. This allows for a quick disconnect from the cable. In this case, it may be better to use a right angle connector, so the bend radius of the cable is not hanging loose. A second option is to install a sensor with cable out. This can have flying leads or a connector added to the end.  At times, when there is not enough room to add a cordset, the cable out gives extra space.

To learn more about welding best practices visit www.balluff.us.

Which cable jacket is best for your application?

There are many different types of cable jackets and each jacket works well in a specific application.  The three main sensor cable jackets are PVC (Polyvinyl Chloride), PUR (polyurethane) and TPE (thermoplastic elastomer). Each jacket type has different benefits like washdown, abrasion resistant or high flexing applications.  Finding the correct jacket type for your application can extend the life of the cable.PVC

PVC is a general purpose cable and is widely available.  It is a common cable, and typically has the best price point.  PVC has a high moisture resistance, which makes it a good choice for wash-down applications.

PURPUR is found mostly in Asia and Europe.  This cable jacket type has good resistance against abrasion, oil and ozone.  PUR is known for being Halogen free, not containing: chlorine, iodine, fluorine, bromine or astatine.  This jacket type does have limited temperature range compared to the other jacket types, -40…80⁰C.

TPETPE is flexible, recyclable and has excellent cold temperature characteristics, -50…125⁰C.  This cable is resistant against aging in the sunlight, UV and ozone.  TPE has a high-flex rating, typically 10 million.

The table below details the resistance to different conditions. Note that these relative ratings are based on average performance. Special selective compounding of the jacket can improve performance.

ResistanceTo

Choosing the right jacket type can help reduce failures in the field, reducing downtime and costs.  Please visit www.balluff.us to see Balluff’s offering of sensor cables in PVC, PUR and TPE.