Premier Manufacturer
Strain relief is essential for ensuring the long life and reliability of connections made on plugs and outlets with flexible cables and protective measures that safeguard cables and hoses from the mechanical stresses induced by pulling, bending, and twisting. In this blog post, we discuss how this protective device works in a wired world, its significance, the various kinds available, and how a suitable one can be decided on, coupled with some pragmatic pointers to make the best choice in real-world applications.
How Strain Relief Works
Strain relief absorbs external forces, such as tension, bending, or twisting, that might damage cables or connectors by holding the cable at the connection point. Thus, strain relief prevents these forces from reaching the inner contacts and keeps sensitive electronic components safe. This is very important when making connections that will stay longer, such as in control cabinets, industrial machinery, and consumer electronics.
It absorbs the stress of physical handling on cables, reducing internal wear and tear on the components and lengthening the cables’ life.
Why Cables Need Strain Relief
Mechanical stress occurs in cables due to their pulling, bending, or continuous movement. Over time, these forces may cause the cable to stretch or bend at too sharp an angle or even pull out of its housing, ultimately failing. Without strain relief, cables are highly susceptible to damage, translating to downtime and extremely costly repairs.
In a factory where machinery is constantly in motion or vibrating, the cables are prone to being tugged or even twisted out of place. A strain relief device holds the cable in place and protects it and the equipment it connects to.
In static systems, strain relief stabilizes the cables, thus preventing accidental disconnections or decreases in performance resulting from the continuous stress placed on them by the environment.
Types of Strain Relief
There are various strain relief designs tailored to specific applications. The most common types include dome-style and flex-style, each offering different levels of protection based on flexibility and rigidity.
Dome-Style Strain Relief
Such a strain relief provides the cable with considerable protection against cutting and is usually made from materials like aluminum, brass, steel, or rigid materials such as nylon. Dome-style strain reliefs are the most appropriate when increased mechanical fixing is demanded from more complex installations like industrial machinery or control cabinets.
Flex-Style Strain Relief
Flex-style devices are generally more flexible and intended to protect cables from crimping damage in fluid applications such as robotics or continuous motion. Materials commonly used include rubber, TPR, and flexible plastics, allowing greater flexibility without compromising protection. They are commonly found in industries where cables undergo lots of bending or vibration, including automotive manufacturing and robotics.
Other Strain Relief Options
In addition to dome and flex styles, other devices provide strain relief in different forms:
- Wire Ties bundle cables together, keeping them organized and preventing unnecessary movement. They are often used in conjunction with strain relief systems in places where cables need to stay grouped but protected.
- Cable Lands offer a sealing solution at the point where cables enter equipment, protecting against environmental factors like moisture or dust.
- Cable Bushings: These protect cables from abrasion as they pass through holes or entry points in enclosures, preventing wear from sharp edges.
- Romex Connectors: Commonly used for non-metallic sheathed electrical cables, providing strain relief and secure connections in electrical work.
Design Considerations for Strain Relief
When choosing the proper strain relief for your application, consider the following factors:
- Size: The strain relief must match the dimensions of your hardware, such as connectors, cable glands, or bushings. The correct fit ensures the strain relief performs as intended without adding unnecessary bulk.
- Materials: Different materials offer varying levels of protection. For example, aluminum and brass are lightweight and anti-corrosive, while PVC and nylon are flexible and provide electrical insulation. Steel and stainless steel are highly resistant to mechanical stress and harsh environments.
- Environment: Consider the operating environment—flexible strain reliefs are ideal for dynamic applications, while rigid types are better suited for static setups. For instance, in food processing environments, where cables must withstand frequent cleaning and harsh conditions, solid, easy-to-clean strain relief made of stainless steel might be the best option.
Pro Tip: When selecting strain relief for a project, it’s essential to factor in the strain level the cable will experience. Flexible strain relief will be the best choice if your cables are part of a moving robotic arm. However, rigid strain relief may be more effective for long-term protection for cables that remain in one place, such as in a control panel.
Applications and Industries
Strain relief is used across many industries where cables face mechanical stress, including:
- Mechanical and Plant Engineering: Ensuring that cables and hoses stay securely in place in industrial machinery.
- Food and Beverage: Protecting cables from damage in environments where cleanliness and durability are essential.
- Medical: Ensuring reliable cable connections in sensitive medical equipment.
- Automotive: Providing strain relief for engine cables or moving parts exposed to constant vibration.
Proper strain relief is crucial to maintaining the system’s integrity in any setting where cables are subject to strain. For systems automotive production lines, flexible strain relief can help ensure that cables in moving robots stay intact and function properly.
Conclusion
Strain relief is an indispensable component that ensures the durability and functionality of cables and hoses, preventing premature wear caused by mechanical stresses. Whether you’re in robotics, food processing, or industrial, the proper strain relief can significantly extend the lifespan of your cables, reduce maintenance costs, and improve system performance.
Final Tip: Evaluate your cables’ needs and choose strain relief according to the wires. A small investment will save you time, money, and hassle.
Romtronic is a specialized manufacturer of customized wire harnesses and cable assemblies with extensive experience in strain relief. Whether your business area is industrial machinery and equipment, medical devices or automotive, we can provide customized solutions to your system’s specific requirements.
Sam Wu is the Marketing Manager at Romtronic, holding a degree in Mechatronics. With 12 years of experience in sales within the electronic wiring harness industry, he manages marketing efforts across Europe. An expert in cable assembly, wiring harnesses, and advanced connectivity solutions, Sam simplifies complex technologies, offering clear, actionable advice to help you confidently navigate your electrical projects.
