Determining Wire and Cable Lifespan: Your Simple Guide

Determining the longevity of wires and cables involves various considerations.

The Arrhenius Equation provides a useful method based on temperature and reaction time. It suggests that for every 10-degree temperature increase, the insulation lifespan of the cable is halved, and vice versa. 

At Digcue, we conduct comprehensive tests to assess the durability of our wires and cables.

1. Pull Testing

Pull force testing evaluates the tensile strength of wires by measuring the force required to separate crimped terminals. Properly attached terminals are crucial to prevent device failure. Our wire pull testers consist of a test stand, load sensor, and gripping attachment. The tester gradually applies force until the terminal disconnects or the wire breaks.

2. Bend Testing

Bend testing assesses the ductility of wires subjected to mechanical stresses. It determines the number of bends a wire can withstand before breaking. Our bend testing machine allows adjustment of wire angles, radius, and loads. Non-destructive testing identifies the bending limit before wire breakage, while destructive testing determines the load needed for a break.

3. Torsion Testing

Torsion testing, or twist testing, evaluates wire resistance to twisting along its axis. It measures maximum torque, torsional shear stress, and breaking angle. This test is vital for devices prone to torsional loads, such as metallic bone screws or rubber tubing in earphones. A longitudinal sample is twisted until failure, recording force, torque, or angular displacement.

4. Push Testing

Push testing, also known as reverse pull testing, applies downward loads onto wires. This test determines the wire's force threshold, either non-destructively or destructively. Non-destructive testing assesses part performance through cyclic loading.

5. Circle Testing 

Circle testing, or conical testing, assesses wire resilience to circular bending. Digcue has developed specialized machines for this purpose, particularly used for testing Apple devices.

6. Others-Additional Wire and Cable Tests

Fatigue Test

Wires and cables, especially those used in speakers, undergo continuous vibration, making them susceptible to deformation and fatigue. Conducting a fatigue test on our wires and cables helps determine if they can withstand prolonged use without succumbing to fatigue.

Constant/High Temperature and Humidity Test

Evaluating products under constant or high temperature conditions assesses their performance in environments with elevated temperatures and humidity levels.

Salt Spray Test

In the automotive industry, a salt spray test is essential to protect wires from corrosion, particularly in regions where salt is used to melt snow on roads during winter. This test simulates corrosion to ensure wires in the engine endure exposure to road salt.

Drop Test

The drop test examines how our cables respond to sudden accelerations or shocks, providing insights into their durability and resilience.

Friction Test

For products subjected to daily use, such as earphones or charging cables, friction is inevitable. Conducting a friction test on our cables helps assess their ability to withstand constant friction encountered during regular usage.