By Eileen Harvey
Servo systems are undeniably the backbone of modern industrial automation, robotics, CNC machinery and a plethora of motion control applications. These systems are designed to provide precise control over movement, making them essential in a wide range of industries, from manufacturing and aerospace to automotive and medical devices. At the heart of these intricate systems lies a crucial yet often overlooked component: the servo cable.
While many may view cables as mere conduits for power and signals, the reality is that the choice of servo cable significantly impacts the overall performance and reliability of the entire system. From transmitting electrical signals with minimal loss to ensuring that power reaches the servo motor without interruption, the right cable selection is paramount. Choosing the appropriate servo cable is not merely a matter of convenience; it’s a strategic decision that can affect long-term operational efficiency, effectiveness and precision in your applications.
Why Servo Cables Matter
Servo cables transmit power, feedback and control signals between servo motors and drives. A poorly chosen cable can result in signal loss and motor miscommunication, excessive wear and mechanical failure, downtime due to a cable breakdown in harsh conditions and increased maintenance costs.
For industries like robotics, CNC machining, packaging and motion control systems, using the right servo cable directly impacts precision, safety and productivity.
Key Factors in Selecting Servo Cables
Selecting the right servo cable starts with understanding the electrical requirements of the application. The cable must support the system’s voltage rating, which is commonly 300V, 600V or 1kV, and its current carrying capacity must match the servo motor’s demands by using the appropriate conductor size. High-speed motors also require cables that can handle higher frequencies without overheating. TKD Kabel offers Kaweflex 2x Shielded EMC optimized servo and VFD cables in sizes from 14 AWG to 6 AWG to support a wide range of electrical loads.
Shielding is another essential factor because electromagnetic interference (EMI) can cause communication errors in servo systems. Single shielding can work in low noise environments, while double shielding that combines foil and braid provides maximum EMI and RFI protection for industrial automation. Proper grounding is also necessary to prevent signal disruption.
Mechanical performance is equally important since servo cables often operate in applications with continuous motion and tight bending. High flex designs are ideal for drag chains and robotics, and the bending radius must always align with manufacturer specifications. Torsion resistance is especially critical for robotic arms that twist and rotate during operation.
Environmental conditions should also guide selection. Many servo cables must resist oil exposure in machining applications, withstand UV for outdoor use or tolerate strong cleaners in packaging and food processing environments. Temperature tolerance is another consideration, particularly in systems exposed to extreme cold or high heat.
Finally, every servo cable should meet the appropriate industry standards. UL and CSA certifications are essential for North American installations, CE and RoHS compliance is required for European safety and environmental standards and certain machines may impose additional regulatory requirements.
Comparing Different Types of Servo Cables
Servo cables come in several jacket and construction types, each suited to different environments and motion requirements. PVC jacket cables are cost-effective and work well in fixed installations where motion is limited. PUR jacket cables offer high flexibility plus strong abrasion and oil resistance, making them ideal for moving systems. TPE jacket cables provide excellent chemical and temperature resistance and are often used in specialized industrial settings. Hybrid servo cables combine both power and signal conductors in a single assembly, which helps simplify installation and reduce overall system complexity.
Application-Specific Considerations
The demands of the application play a major role in cable selection. Robotics systems require high flexibility and strong torsion resistance to accommodate continuous movement and rotation. CNC machines benefit from oil-resistant and well-shielded cables that maintain reliable performance under harsh machining conditions. Packaging systems rely on lightweight flexible cables that can withstand fast repetitive motion, while conveyors often involve long-distance cable runs where low loss and effective shielding help maintain signal and power integrity.
Best Practices for Choosing the Right Cable
Choosing the best servo cable involves looking beyond immediate needs. It is wise to consider future scalability and select cables that provide headroom for system upgrades. Datasheets should always be checked to ensure every rating aligns with the servo drive and motor specifications. Evaluating total cost of ownership is also essential because higher-quality cables can reduce downtime and replacement expenses over time. When questions arise, consulting experts such as those at TKD Kabel can provide valuable technical guidance for making the right selection.
Facts About Servo Cables
- High-flex servo cables can withstand 10+ million bending cycles.
- Shielded cables reduce EMI by up to 90%, ensuring stable motor communication.
- PUR-jacketed cables are 5x more resistant to abrasion than PVC.
Tips and Recommendations
- Always route servo cables separately from high-voltage power cables to reduce interference.
- Use strain reliefs to prevent connector damage.
- For outdoor systems, invest in UV-resistant jackets.
- Choos Kaweflex cables for EMC-optimized performance in automation and CNC environments.
Choosing the right servo cable is essential for maximizing the performance, safety and durability of your servo systems. By evaluating electrical requirements, shielding, mechanical stress, environmental conditions and compliance standards, you can ensure optimal results for your application.
Explore the full range of TKD Kabel through L-com. We’ll fill your orders fast, with same-day shipping on all qualified, in stock, online orders received Monday through Friday before 5 p.m. EST. For TKD-related inquiries, connect with our U.S-based TKD expert Eileen Harvey at eharvey@infiniteelectronics.com.
