What are the situations of cable breakage?

(1) Material and design defects
① Improper selection of outer sheath material: for example, failure to choose oil resistant rubber material in environments with oil stains; Failure to use materials with good cold resistance in low-temperature environments may result in premature damage or even rupture of the external protective layer.
② The conductor cross-section is too small: In order to pursue better flexibility, copper wire with a smaller diameter is selected as the conductive core wire. Although it increases flexibility, it reduces mechanical strength and is prone to breakage due to fatigue after frequent bending.
③ Lack of effective anti twist structure: Especially for drag chain cables that need to be used on mobile devices, if the design of their internal braided layer is not sufficient to resist repeated twisting forces, it is easy to self entangle and eventually break.
(2) Installation and operational errors
① Insufficient bending radius: In many cases, people neglect to set the minimum bending radius according to the manufacturer's recommended standards (usually more than 8 times the outer diameter of the cable), which causes the cable to be damaged in a short period of time due to excessive bending.
② Multiple cables are tightly tied together: this not only affects the air circulation between each cable, causing heat accumulation and accelerating the aging process, but also increases the chance of mutual friction, further exacerbating the degree of wear.
③ Overloaded stretching use: For example, if the specialized cables used in heavy machinery such as cranes are not properly supported or fixed in place, they are highly likely to be forcibly pulled apart under the action of huge tensile forces for a long time.
(3) Environmental and External Damage
① Natural erosion under extreme conditions: Failure to select products with good heat resistance correctly in high-temperature workshops, or lack of corresponding protective measures in work areas exposed to corrosive substances, can cause irreversible damage to cables.
② Unexpected impact and continuous vibration effects: Whether it is the sudden falling of external objects towards the running circuit or the periodic vibration generated by mechanical equipment itself, it may cause rapid degradation of local areas until complete failure.
③ Chemical reactions caused by water intrusion: Especially for cables laid underground or in humid environments, improper waterproof sealing can easily lead to rusting and corrosion of internal metal components, thereby affecting the overall functionality.
(4) Production process issues
① Limitations of Layered Cabling Technology: Although this method can reduce costs to some extent, the lack of sufficient tight connections between each subunit poses significant physical stress challenges to the entire system, especially in dynamic application scenarios where spiral cracks are more likely to propagate to the point of complete disconnection.
② Quality issues that arise during the manufacturing process, including but not limited to uneven insulation layer thickness and improper distribution of fillers, can affect the quality level of the final product and shorten its service life.
(5) Sudden load impact
① The instantaneous high current surge generated when encountering situations such as emergency braking of large vehicles or short circuits in electrical systems can also pose a great challenge to all connected components, and in severe cases, can directly lead to the complete damage of certain weak links that cannot be repaired.