Cables And Wires Sensor Cables for Comprehensive Environmental Monitoring

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SAB Bröckskes GmbH & Co KG

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When designing cables for environmental monitoring, specific material and construction requirements must be considered depending on the area of application. In close consultation with its customers, SAB Bröckskes defines the specific criteria regarding environmental compatibility, robustness, weight, insulation, and sheath materials through requirements engineering.

Meaningful environmental monitoring creates data-based values through precise recording and evaluation of bioindicators. Based on this data, well-informed decisions can be made to conserve resources and preserve nature and quality of life. The range of applications is enormous and is constantly expanding:

• from long-term monitoring of air and water quality to
• sample analysis for the examination of operational surface water to
• real-time monitoring of the water levels of our bodies of water.

Using ground-integrated measuring systems, sensors provide precise values for ground compaction and erosion, for example, in land development projects. Based on bioindicators, urban developers draw conclusions about air quality and noise pollution. With the help of probes, early warning systems can continuously monitor water levels and flow velocities of rivers. The biodiversity of ecosystems can also be accurately monitored through the installation of optical detection systems.

Requirements Engineering for Sensor Cables

For all monitoring tasks, the reliability and durability of the sensor systems used are crucial. Wired connections have proven to be a robust and reliable solution. Depending on the sensor and measurement task, high transmission performance and data rates can be achieved via USB 3.0 and Gigabit Ethernet.

To optimally adapt the cable design to the sensor measurement systems and specific application areas, the special cable manufacturer SAB Bröckskes conducts requirements engineering. The process takes into account all aspects relevant to cable construction, starting with the demands of various stakeholders on monitoring:

• Cable structure,
• Insulation and sheath materials
• Maximum cable weight.

It must be clarified, for example, whether the sensors with direct environmental contact can be connected using the same cable design as remotely located evaluation units, or whether the specific cable weight is suitable for use as floating or submersible cables. Environmental conditions also play an important role in the choice of sheath material. For instance, a cable sheath that allows environmentally friendly use in sensitive environments due to its low plastic additives may still prove unsuitable because of additional UL approval requirements regarding its fire behavior.

Sustainable, Environmentally Friendly Cable Design

In line with its intended use, the sustainability of raw materials and manufacturing processes takes center stage in the requirements engineering of sensor cables for environmental monitoring.

The cable design should be configured to exert as little negative impact on the operational environment as possible. For example, with a level probe weighing approximately 4 oz, a 66 ft long connection cable can increase the total weight sixfold. If the material combination involves critical raw materials and/or unsustainable manufacturing processes, the ecological footprint negatively outweighs the intended purpose of use. "In that case, the cable would be part of the problem rather than part of the solution for greater environmental protection and sustainability," says Marc Gerlatzek, Business Development for Medical Technology and Assembly at SAB Bröckskes. "This is why we place great importance on sustainability in production and material selection. Not just in our COC, but also through concrete measures and product innovations," Gerlatzek explains. He adds: "This applies to our SAB organic series, whose sheath material is made of approximately 45 percent ecological, environmentally friendly raw materials. This reduces the CO₂ footprint by an average of 25 percent compared to similar fossil-based products. We source the materials from short, regional supply chains. Furthermore, we now generate a quarter of our production's electricity consumption renewably from our own PV systems."

Special Cable Manufacturing According to Series Standards

SAB Bröckskes is one of the world's leading manufacturers of cables and wires, cable assemblies, and temperature measurement technology. The company has over 75 years of experience in cable and wire manufacturing as well as in temperature measurement and control technology and has grown from a one-man operation to a globally operating provider with 550 employees. In addition to producing standard cables and wires “Made in Germany,” one of its key strengths lies in the construction of custom-made solutions. Each year, SAB Bröckskes produces more than 1,500 specialty cables tailored to customer requirements. To realize the wide range of customer-specific modifications, the Viersen-based cable specialist relies on close customer contact.

Since all cable productions are carried out exclusively on series machines, every prototype is simultaneously a series product suitable for presentation to the Notified Body. Functional measurements on the specialty cables, which can be produced in lengths starting from 328 ft depending on the design, can be performed under real conditions both on the bulk material and on the assembly. If necessary, construction adjustments are made based on measurement results in coordination with the customers. “This approach ensures successful project execution and provides our customers with reliable, durable cable solutions tailored precisely to their applications,” summarizes Marc Gerlatzek.

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