Industrial automation depends on reliable communication between controllers, sensors, drives and other connected devices. As manufacturing systems become more automated, communication networks need to transfer data quickly and consistently while operating in demanding environments. PROFINET has become an important Industrial Ethernet standard for applications where real-time communication and flexible network structures are required.
While network performance is important, the physical cable also plays a major role in a PROFINET installation. This becomes particularly relevant when cables are installed on moving machinery, where repeated bending and mechanical stress can affect conventional cables.
What Is PROFINET?
PROFINET is an Industrial Ethernet communication standard developed for automation applications. It uses Ethernet technology and supports communication between control systems and field devices.
One of its important characteristics is its ability to support real-time communication. This makes PROFINET suitable for applications where machines need to exchange data efficiently and respond to changing operating conditions.
PROFINET IO is commonly used for communication between an IO controller and distributed IO devices. This architecture can be found in manufacturing equipment, mechanical engineering and drive technology.
Why PROFINET Cables Matter
A communication network is only as reliable as its physical infrastructure. While controllers and network devices receive considerable attention during system design, cable selection is equally important.
In a fixed installation, a network cable may experience very little mechanical movement. However, industrial machines often have moving axes, robotic arms or travelling components. When the cable moves continuously, it can experience repeated bending and mechanical stress.
Using a cable designed specifically for dynamic applications can help address these challenges.
PROFINET in Moving Applications
PROFINET is used across a wide range of automated equipment, including production machines, packaging machinery, machine tools and robotic systems. In many of these applications, network cables are installed inside energy chains to safely guide them as machine components move.
A cable used in an energy chain needs a construction that can withstand repeated movement while maintaining reliable data transmission. Cable geometry, conductor construction, shielding and jacket material can all influence performance.
This is why industrial PROFINET cables intended for continuous movement differ from cables designed primarily for stationary installations.
Key Factors When Selecting a PROFINET Cable
Several factors should be considered when choosing a PROFINET cable for an industrial application.
1. Type of Movement
The first consideration is how the cable will move. Some applications involve simple back-and-forth travel, while others involve high-speed or more complex movements.
The cable construction should match the movement profile of the machine.
2. Bend Radius
The minimum bend radius is particularly important in energy-chain applications. Repeatedly bending a cable below its specified radius can increase mechanical stress and potentially reduce its service life.
The available installation space and the energy chain's specifications should therefore be considered during cable selection.
3. Environmental Conditions
Industrial machinery can expose cables to oil, coolants, chemicals, abrasion and temperature fluctuations. Different jacket materials may be appropriate for different environments.
Selecting the cable based on actual operating conditions can help improve long-term performance.
4. Data Transmission Requirements
The cable must also meet the communication requirements of the PROFINET system. Network architecture, transmission distance and the connected devices should be considered when selecting the appropriate cable.
Electrical characteristics and mechanical performance should be evaluated together rather than independently.
PROFINET Cables for Energy Chains
Energy chains provide a controlled path for cables on moving machinery. They help maintain an organised routing system and control the cable's bending radius during machine movement.
For applications involving continuous motion, PROFINET cables from igus are available in different cable qualities and jacket materials for various industrial requirements. The chainflex® range includes PROFINET cables developed specifically for permanent movement in energy chains, including options for demanding applications and different bend-radius requirements.
The available cable construction should be selected according to the machine's movement, environmental conditions and required service life.
Applications of PROFINET Cables
PROFINET cables can be found in many areas of industrial automation. Manufacturing equipment may use them to connect controllers with distributed devices, while machine tools can use them for communication between automation components.
Robotics is another important application. Automated robots require communication with controllers and other equipment while performing repetitive movements. A suitable dynamic cable can help maintain the connection as the robot operates.
Packaging machines, assembly equipment and material-handling systems can similarly require PROFINET connections in moving sections of the machine.
PVC, PUR and TPE Cable Options
The operating environment can influence the choice of outer jacket material. PVC, PUR and TPE are among the materials used in industrial cable construction, with different properties suited to different applications.
For example, an application with exposure to oils or demanding mechanical conditions may require different material characteristics from a relatively clean indoor installation.
The right choice therefore depends on the specific machine environment rather than simply selecting a cable based on its communication standard.
Testing and Service Life
Cable reliability is particularly important in automation because an unexpected network cable failure can interrupt machine operation. Testing moving cables under realistic conditions can provide useful information about their expected performance.
The chainflex® range is tested for dynamic applications, and igus provides service-life information and calculation tools for selected cables. Its PROFINET range includes multiple cable qualities intended for different application requirements.
Such information can help engineers compare cable options based on the actual movement profile of their equipment.
Conclusion
PROFINET provides an effective communication technology for modern industrial automation, but selecting the right physical cable is essential when the network operates in a moving application.
Engineers should consider movement type, bend radius, environmental conditions, data transmission requirements and expected service life before choosing a cable. For machinery where network cables move continuously inside energy chains, a cable specifically developed for dynamic applications can be an important part of a reliable automation system.
By combining appropriate network technology with properly selected cabling, manufacturers can build communication systems that support efficient and dependable machine operation.