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Circular cable assemblies have become a rapidly growing product line for industrial device companies. Unlike standard cable types where the components are kept in a single straight line, circular cable assemblies take up a more elaborate shape. Apart from simple cable components such as conductors, connectors, and insulation, they can incorporate a wide range of components such as filters, relays, and transformers. These components are ingeniously placed within the same cable loop and aid in providing a comprehensive and efficient product range.

This article will focus on the various application fields of circular cable assemblies and provide a working principle of the same.

Application Fields

Circular cable assemblies are used in many different industries, with most of them concentrating on high-performance consumer, industrial, and military applications. Because they are meticulously designed to meet the customers’ requirements, circular cable assemblies are ideal for applications that need great flexibility and feature intricate shapes.

Circular cable assemblies are deployed in military equipment to provide optimal data transmission and communications. They are also used in critical applications like flight controls, actuators, robotics, antenna systems, sensors, navigation, data transmission, and more. Moreover, they are often used in the telecommunications industry, where they can be found in innovative wireless networks, surveillance systems, or voice radios.

In the medical field, circular cable assemblies are used for a plethora of applications such as cardiology, radiology, and imaging. They are capable of withstanding tough conditions while still maintaining their integrity. Plus, they are used to manufacture medical devices such as X-Ray machines, hospital beds, ultrasound systems, blood analyzers, and more.

Circular cable assemblies are also found in consumer electronics applications such as wearable fitness trackers, digital cameras, MP3 players, cell phones, tablet PCs, as well as in industrial automation applications, helping to regulate manual processes from one location.

Working Principle

A typical circular cable assembly features a main upper part called the sheath and a lower part called the core. The sheath is the protective layer around the core. The center of the sheath is hollow, which allows the core to be inserted and secured in place. Typically, the sheath consists of two pieces (top and bottom) that are snapped together. However, some designs use rivets or welding instead.

The core consists of multiple cables that are wrapped together in a bundle. Depending on the application, the number and type of cables increase. Common cables that are found in the core are data cables, power cables, and coaxial cables.

The cables are housed within one or more strength members. Strength members provide extra support to the cables and improve the overall durability of the assembly. The strength members can also be used to provide additional flexibility or rigidity, which helps the cable bend more easily or more tightly in certain areas.

The cables are then surrounded by a shield. The shield protects the cable from physical damage such as crushing, tearing, and abrasions. It also reduces the amount of electromagnetic interference (EMI) that is transmitted between the core and the surrounding environment.

In addition to the core and the shield, some circular cable assemblies also have an additional layer of insulation for extra protection. This insulation is usually applied between the shield and the core and helps to ensure that the cable and its components are correctly insulated. It also helps to protect the cable from material fatigue, temperature extremes, and other environmental factors.

Overall, circular cable assemblies are incredibly versatile and can be used in a number of applications. They can provide robust performance in extreme conditions and provide increased flexibility, safety, and performance over traditional cabling.

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