Custom Hybrid Power & Signal Cable | 2x2mm²+4x2x0.15mm²(twisted pairs with foil shielded)
CUSTOM HYBRID POWER & SIGNAL CABLE: INTEGRATED SOLUTION FOR COMPLEX SYSTEMS
Our Custom Hybrid Power & Signal Cable represents sophisticated cable engineering for applications requiring simultaneous power delivery and shielded signal transmission. This advanced cable integrates 2 power conductors of 2mm² with 4 individually AL-PET shielded twisted pairs of 0.15mm², all protected by FEP insulation, comprehensive tinned copper wire braiding (≥80% coverage), and a durable TPV outer sheath. Rated for operations from -40℃ to +120℃ with a 2000V/min test voltage, this 7.9mm OD cable provides a streamlined solution for industrial automation, robotic systems, and complex machinery where both power and clean signal transmission are critical in a single, organized assembly.
KEY FEATURES & TECHNICAL ADVANTAGES
✔ Integrated Hybrid Design - Combines 2x2mm² power conductors and 4x2x0.15mm² shielded signal pairs in one optimized cable
✔ Superior Signal Integrity - Individual AL-PET shielding on each signal pair minimizes crosstalk and EMI interference
✔ Comprehensive EMI Protection - Overall tinned copper braiding (≥80%) provides additional electromagnetic shielding
✔ Wide Temperature Range - TPV sheath maintains flexibility and performance from -40℃ to +120℃
✔ Enhanced Safety - 2000V/min test voltage ensures robust insulation integrity and safety margin
SPECIFICATIONS & CONSTRUCTION
| Component | Specification |
|---|---|
| Power Conductors | 2x2mm², TC (Tinned Copper, 19/0.37), FEP Insulation |
| Signal Conductors | 4x2x0.15mm², TC (Tinned Copper, 39/0.07), FEP Insulation |
| Signal Pair Shielding | Individual AL-PET (Aluminum-Polyester) Shield |
| Overall Shielding | Tinned Copper Wire Braiding (≥80% coverage) |
| Outer Sheath | TPV (Thermoplastic Vulcanizate) |
| Wire Diameter | Power: ~2.5mm, Signal: ~0.90mm (after insulation) |
| Overall Diameter | 7.9mm |
| Temperature Rating | -40℃ to +120℃ |
| Test Voltage | 2000V/min |
WHY CHOOSE OUR CUSTOM HYBRID CABLE?
We specialize in engineering integrated cable solutions that simplify complex system designs. This hybrid cable eliminates the need for separate power and signal cables, reducing installation time, minimizing clutter, and decreasing points of failure. The individual AL-PET shielding on each signal pair ensures exceptional signal integrity even when routed alongside power conductors, while the overall tinned copper braid provides additional protection against external EMI. The TPV sheath offers an excellent balance of flexibility, temperature resistance, and environmental durability. With extensive experience in automation and robotics cabling, we deliver solutions that optimize both performance and installation efficiency.
TYPICAL APPLICATIONS
• Industrial Robotics - Integrated wiring for robot arms combining motor power and encoder/sensor signals
• Factory Automation - Machine wiring requiring both actuator power and control/feedback signals
• Medical Equipment - Devices needing combined power supply and data transmission
• Test & Measurement Systems - Equipment requiring synchronized power and signal channels
• Automated Machinery - Complex systems where cable consolidation improves reliability and maintenance
- Request Sample & Compliance Data - Evaluate this hybrid solution in your application
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Download Technical Specifications - Get detailed construction and performance data
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Contact Our Engineering Team - Discuss customization for your specific requirements
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Get Competitive Quotation - OEM/ODM solutions with design modifications available
FAQ
Q1: What is the advantage of individual pair shielding versus overall shielding only?
A: Individual AL-PET shielding prevents crosstalk between adjacent signal pairs and isolates them from the power conductors, which is critical for maintaining signal integrity in hybrid cables carrying both power and sensitive signals.
Q2: Why choose TPV sheath instead of PVC or PUR?
A: TPV offers excellent flexibility across a wide temperature range (-40℃ to +120℃), good chemical resistance, and weatherability without the plasticizer migration issues of PVC or the moisture sensitivity of some PUR formulations.
Q3: Can the power and signal conductors be used for different voltage levels?
A: Yes, the FEP insulation and individual shielding allow different voltage applications on different conductors, though all circuits share the same overall cable rating and should be designed accordingly.
Q4: What is the benefit of the 39/0.07 stranding for signal conductors?
A: The 39/0.07 ultra-fine stranding provides exceptional flexibility for the small signal conductors, which is important in dynamic applications and helps prevent conductor fatigue in moving installations.
Q5: Can this design be modified with different conductor configurations?
A: Absolutely. We can customize various power/signal combinations, conductor sizes, shielding options, and sheath materials to create the ideal hybrid solution for your specific application needs.