The industrial automation industry is developing rapidly, continuously improving production efficiency, quality and sustainability by integrating advanced technologies such as IoT, AI and robotics.
Automation cables (Automation cable, Robotics cable, AI cable) play a vital role in the field of industrial automation. They are not only used for data transmission, but also for power distribution and signal control.
Below, China Custom Cable Manufacturer TST CABLES will introduce several common custom automation cable types, bus technology, and working principles in detail. If you have questions about automation cables after reading this article, please communicate with our engineers via email.
Introduction to Automation Cables
Complex automated industrial systems (such as manufacturing assembly lines) require an organized controller system hierarchy to fully function. In this hierarchy, there is usually a human-machine interface (HMI) at the top, where the system is operated and monitored. This is usually linked to the programmable logic controller (PLC) in the middle layer through a non-time-critical communication system (such as Ethernet). At the bottom of the control chain is the fieldbus, which connects the PLC to the components that actually perform the work, such as sensors, actuators, motors, control consoles, switches, valves, and contactors.
Fieldbus works on a network structure, usually allowing daisy chain, star, ring, branch and tree network topologies. Previously, computers were connected using RS-232 (serial connection), and only two devices could communicate. Fieldbus only requires one communication point at the controller level, and then allows multiple (hundreds) of analog and digital points to be connected simultaneously. This reduces both the length of the required cable and the number of cables required.
Features of Automation Cables
Anti-interference: Automation cables usually have a shielding layer, which can effectively resist electromagnetic interference.
Durability: With high-quality materials and design, it can work stably for a long time in harsh industrial environments.
Flexibility: With good bending performance, it is suitable for equipment that needs to be moved frequently.
Temperature resistance: It can work in a wide temperature range and is suitable for different environmental conditions.
Connectors: Equipped with professional connectors to ensure connection reliability and signal integrity.
- Profibus Cable
Profibus (Process Field Bus) is an open fieldbus standard widely used in automation and process control. It supports three communication services: Profibus DP (Decentralized Peripherals) for high-speed device-level control; Profibus FMS (Fieldbus Message Specification) for workshop-level communication; and Profibus PA (Process Automation) for process automation. Profibus cables have a shielding layer that can effectively resist electromagnetic interference.
- CAN bus
CAN bus (Controller Area Network) is a multi-master bus architecture used for real-time applications, especially in the fields of automotive and industrial automation. The CAN bus uses twisted pair cables for data transmission and supports data rates up to 1 Mbit/s. CAN cables usually have high impedance and shielding layers to ensure signal integrity. - ASI bus
ASI bus (Actuator-Sensor Interface) is a low-cost fieldbus mainly used for simple sensor and actuator connections. The ASI bus supports a data rate of 30 kbit/s and is suitable for simple automation tasks. ASI cables usually use shielded twisted pair cables to reduce interference. - InterBus cable
InterBus is a single-wire bus system used for distributed automation applications. It can support up to 1000 devices and has high flexibility and reliability. InterBus cable uses shielded twisted pair to ensure the quality of signals in long-distance transmission. - DeviceNet cable
DeviceNet is a fieldbus standard based on CAN technology, developed by Rockwell Automation. It supports communication between various devices such as sensors, actuators and controllers. DeviceNet cables usually have a shielding layer to reduce interference. - Safety Bus
Safety Bus is a bus technology specially designed to ensure safety-critical applications. For example, SafetyBus f and ProfiSafe are two common safety bus standards. These buses use redundant paths and special communication protocols to ensure the safety and reliability of the system. Safety bus cables usually have additional shielding layers and enhanced mechanical strength. - Ethernet Category 5 (Cat 5), Category 5e (Cat 5e), Category 6 (Cat 6), Category 6a (Cat 6a), Category 7 (Cat 7)
Ethernet is a widely used local area network technology that has been widely used in industrial automation in recent years. Industrial Ethernet standards such as EtherCAT, Profinet, and Ethernet/IP support high-speed data transmission with low latency. Ethernet cables (such as UTP (Unshielded Twisted Pair) Cat 5e or Cat 6) usually have a shielding layer to reduce electromagnetic interference. TST CABLES’s Ethernet cable product line covers a variety of Ethernet cables such as UTP, STP, FTP, S/FTP, SFTP, SC, MPO, etc. - Sensor Cables
Sensor cables are cables designed specifically for sensors to connect sensors and control systems. They usually have shielding layers and high-precision conductors to ensure accurate signal transmission. Sensor cables can be customized according to specific application requirements to adapt to different environmental conditions. - Fiber Optic Composite Cables
Fiber optic composite cables use optical signals for data transmission and have extremely high bandwidth and anti-interference capabilities. The fiber optic cables provided by TST CABLES are suitable for various industrial automation applications, including high-speed data transmission, video transmission, and remote control.
Analysis of the working principle of automation cables
Profibus cable
Profibus DP: adopts master-slave communication mode, the master station controls data exchange, and is used for device-level control.
Profibus FMS: message-oriented communication mode, used for workshop-level communication.
Profibus PA: used for process automation, supports intrinsically safe equipment.
CAN bus
Communication protocol: adopts message frame format, supports priority arbitration, and ensures that key data is transmitted first.
Physical layer: uses twisted pair for data transmission, and supports data rates up to 1 Mbit/s.
ASI bus
Communication protocol: adopts simple communication protocol, supports data rates up to 30 kbit/s.
Physical layer: uses shielded twisted pair, suitable for simple sensor and actuator connections.
InterBus cable
Communication protocol: adopts single-line communication technology, supports up to 1,000 devices.
Physical layer: uses shielded twisted pair, with high flexibility and reliability.
DeviceNet cable
Communication protocol: based on CAN technology, supports device-level communication.
Physical layer: Use shielded twisted pair to support data rates up to 1 Mbit/s.
Safety bus cable
Communication protocol: Use redundant paths and special communication protocols to ensure the safety and reliability of the system.
Physical layer: Use cables with additional shielding layers to reduce interference.
Ethernet cable CAT
Communication protocol: Use TCP/IP protocol stack to support high-speed data transmission.
Physical layer: Use shielded twisted pair or optical fiber to support data rates up to 1 Gbit/s.
Sensor cable
Communication protocol: Usually no specific communication protocol is used, but it is directly connected to the control system.
Physical layer: Use cables with shielding layers to ensure accurate signal transmission.
Fiber optic composite cable
Communication protocol: Use optical signals for data transmission, supporting high-speed data transmission.
Physical layer: Use optical fiber cables with extremely high bandwidth and anti-interference capabilities.
Automation cable selection guide:
Common technical parameters and specifications of automation cable products. In addition to the following specifications, other specifications can be customized according to your actual needs. Welcome to email TST cables engineers.
- Profibus Cable
Profibus cable is used for communication protocols such as Profibus DP, FMS and PA, and supports high-speed data transmission. TSTCABLES provides high-quality Profibus cables with excellent shielding effect and anti-interference ability, ensuring the accuracy and stability of data transmission. The following are its technical parameters and specifications:
Conductor: bare copper or tinned copper, diameter 0.5mm to 1.5mm
Insulation: PVC or XLPE
Shielding: aluminum foil shield plus copper braid shield
Jacket: PVC or LSZH
Operating temperature: -40°C to +80°C
Bending radius: at least 10 times the outer diameter of the cable
Maximum voltage: 300V
Impedance: 120Ω ±10%
Attenuation: depends on frequency and length
- CAN bus cable
CAN bus cable is used for protocols such as CANopen and DeviceNet, supporting real-time communication. TST cables’ CAN bus cables are made of high-performance materials, support high-speed data transmission, and have excellent durability and flexibility. The following are its technical parameters and specifications:
Conductor: bare copper or tinned copper, diameter 0.5mm to 1.5mm
Insulation: PVC or XLPE
Shielding: copper braided shield
Jacket: PVC or LSZH
Operating temperature: -40°C to +80°C
Bending radius: at least 8 times the cable outer diameter
Maximum voltage: 30V
Impedance: 120Ω ±10%
Attenuation: depends on frequency and length
- ASI bus cable
TST cables provides ASI bus cables suitable for simple sensor and actuator connections, ensuring reliable data transmission. The following are its technical parameters and specifications:
Conductor: Bare copper or tinned copper, diameter 0.5mm to 1.0mm
Insulation: PVC or XLPE
Shield: Copper braided shield
Jacket: PVC or LSZH
Operating temperature: -40°C to +80°C
Bending radius: at least 6 times the cable outer diameter
Maximum voltage: 30V
Impedance: 120Ω ±10%
Attenuation: Depends on frequency and length
- InterBus cable
InterBus cable is used for InterBus single-wire communication technology. TST cables’ InterBus cables can support a large number of device connections, ensuring efficient communication in distributed automation applications. The following are its technical parameters and specifications:
Conductor: Bare copper or tinned copper, diameter 0.5mm to 1.0mm
Insulation: PVC or XLPE
Shield: Copper braided shield
Jacket: PVC or LSZH
Operating temperature: -40°C to +80°C
Bending radius: at least 8 times the outer diameter of the cable
Maximum voltage: 30V
Impedance: 120Ω ±10%
Attenuation: Depends on frequency and length
- DeviceNet cable
DeviceNet cables provided by TST cables have high reliability and support stable communication between various devices. The following are its technical parameters and specifications:
Conductor: Bare copper or tinned copper, diameter 0.5mm to 1.0mm
Insulation: PVC or XLPE
Shielding: Copper braided shield
Jacket: PVC or LSZH
Operating temperature: -40°C to +80°C
Bending radius: at least 8 times the cable outer diameter
Maximum voltage: 30V
Impedance: 120Ω ±10%
Attenuation: Depends on frequency and length
- Safety bus cable
Safety bus cables are used for safety-related communication protocols such as ProfiSafe and SafetyBus p. TST cables’ safety bus cables are specially designed to meet the requirements of safety-critical applications, ensuring the safety and reliability of the system. The following are its technical parameters and specifications:
Conductor: Bare copper or tinned copper, diameter 0.5mm to 1.5mm
Insulation: PVC or XLPE
Shielding: Copper braided shield
Jacket: PVC or LSZH
Operating temperature: -40°C to +80°C
Bending radius: at least 10 times the cable outer diameter
Maximum voltage: 300V
Impedance: 120Ω ±10%
Attenuation: Depends on frequency and length
- Ethernet Cable
TST cables provides high-speed Ethernet cables for industrial Ethernet communication protocols such as Profinet, EtherCAT and Powerlink, Ethernet/IP. The following are its technical parameters and specifications:
Conductor: Bare copper or tinned copper, diameter 0.5mm to 1.0mm
Insulation: PVC or XLPE
Shielding: Copper braided shield
Jacket: PVC or LSZH
Operating temperature: -40°C to +80°C
Bending radius: at least 8 times the outer diameter of the cable
Maximum voltage: 300V
Impedance: 100Ω ±10%
Attenuation: Depends on frequency and length
- Sensor Cable
TST cables’ sensor cables have high-precision conductors and shielding layers to ensure accurate signal transmission. The following are its technical parameters and specifications:
Conductor: bare copper or tinned copper, diameter 0.2mm to 0.5mm
Insulation: PVC or XLPE
Shielding: copper braided shield
Jacket: PVC or LSZH
Operating temperature: -40°C to +80°C
Bending radius: at least 6 times the outer diameter of the cable
Maximum voltage: 30V
Impedance: Depends on the specific application
Attenuation: Depends on frequency and length
- Fiber Optic Composite Cable
The fiber optic cables provided by TST cables are made of high-quality optical fiber and composite materials, support high-speed data transmission, and are suitable for various industrial automation applications. The following are its technical parameters and specifications:
Fiber: single mode or multimode fiber
Conductor: bare copper or tinned copper, diameter 0.5mm to 1.5mm
Insulation: PVC or XLPE
Sheath: PVC or LSZH
Operating temperature: -40°C to +80°C
Bending radius: at least 10 times the outer diameter of the cable
Maximum voltage: depends on the specific application
Attenuation: depends on the fiber type and wavelength
Transmission rate: depends on the specific application
Customized automation cables in cooperation with cable manufacturer TST CABLES
We are a professional manufacturer focusing on automation cables, able to provide customized solutions for all bus protocols and automation requirements. Our product line covers Profibus cable, CAN bus cable, ASI bus cable, InterBus cable, DeviceNet cable, safety bus, Ethernet, sensor cable and fiber composite cable. We know that each application has its own unique needs, so our products are tailored to the specific requirements of our customers. Whether it is a cable that works in extreme temperature conditions or a cable that needs to withstand heavy objects, we can provide the best solution.
The current Automation Robotics AI industry faces price fluctuations, rising costs and sustainability issues. TST cables industrial IoT cables combine first-principles models and cable engineering expertise to achieve real-time transmission, monitoring and data-driven strategies to support operational efficiency. TST cables customized Automation cable Robotics cable AI cable can improve transmission efficiency, help reduce lost signal errors, improve operational efficiency and accuracy, and reduce costs.
If you need further technical support or customized cable solutions for automation custom cables, you can visit the TST CABLES official website or feel free to send an email to the professional cable engineer of TST cable manufacturer (email: lixiangchao@testeck.com, please state your country, your industry, and your needs in the email).