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What AWG Rating Is Best for Machine Vision Cables?

Choosing the right cable is critical for reliable machine vision performance. One key specification is the AWG (American Wire Gauge) rating. This number indicates the thickness of the electrical conductors inside the cable.

Simply put: A lower AWG number means a thicker wire.

Thicker wires (lower AWG) offer lower electrical resistance. This is crucial because:

Reduced Voltage Drop: Over longer distances, thicker wires minimize the loss of voltage reaching your camera or sensor, ensuring it gets the power it needs.
Better Signal Integrity: For power cables, sufficient thickness ensures stable voltage, preventing camera malfunctions or shutdowns. For data cables (like USB3 Vision, GigE Vision), thicker power conductors within the cable also contribute to overall stability.
Higher Current Capacity: Thicker wires can safely carry more electrical current without overheating.

Thinner wires (higher AWG) are more flexible and take up less space, making cable routing easier, especially in tight spaces or moving applications (like robot arms).

So, What’s the Best AWG for Machine Vision?

There’s no single “best” AWG; it depends on your specific needs:

Power Requirements & Cable Length:
- Longer Distances (e.g., >5-10 meters): Use thicker wire (Lower AWG: 22, 24, or 26 AWG) to combat voltage drop. This is essential for PoE (Power over Ethernet) cameras or any camera needing power over distance.
- Shorter Distances (e.g., <5 meters): Thinner wire (Higher AWG: 26, 28, or even 30 AWG) is often sufficient and offers better flexibility.
Flexibility Needs:
- Fixed Installations: Flexibility is less critical; prioritize lower AWG for power over distance if needed.
- Robotic Arms, Moving Gantries, Tight Bends: Prioritize flexibility. Choose higher AWG cables (e.g., 28 AWG, 30 AWG) designed for continuous flexing. These often use finer stranded wires.
Data vs. Power Cables:
- Data Cables (Ethernet, USB, Coax): The AWG primarily refers to the power conductors within the cable (e.g., for PoE). The signal pairs have their own specifications. Focus on the power conductor AWG based on length/PoE requirements.
- Dedicated Power Cables: AWG is the main factor for current capacity and voltage drop over distance.

Common AWG Ratings in Machine Vision Cables:

24 AWG: Common for PoE applications needing longer runs (e.g., 30m+). Offers good current capacity but less flexible.
26 AWG: A very common, versatile choice. Good balance for moderate-length PoE runs (e.g., up to 15-30m depending on power draw) and general fixed installations. Offers reasonable flexibility.
28 AWG: Excellent flexibility. Often used in shorter cable runs (<5-10m), inside control cabinets, or on robots/moving parts where flexibility is paramount. Check voltage drop for PoE over longer distances.
30 AWG (or higher): Maximizes flexibility for demanding continuous flex applications (e.g., high-speed robots). Primarily suitable for very short runs or situations where minimal power is required.

Key Recommendation:

For most general machine vision applications involving moderate cable lengths (under 10m) and standard PoE cameras, 26 AWG or 28 AWG power conductors offer an excellent balance of performance, flexibility, and cost.
Always consult your camera’s specifications for its power requirements (voltage and current).
Consider the total cable length from the power source to the camera.
Prioritize flexibility if the cable will be moving constantly.

In Summary:

Don’t just pick the thickest or thinnest wire. Match the AWG to your application’s power needs, cable length, and required flexibility. For typical setups, 26 AWG or 28 AWG provides a reliable solution. For long runs, go thicker (lower AWG); for robots and tight bends, go thinner (higher AWG) with a flex-rated cable. Choosing the right AWG ensures your vision system gets stable power and operates reliably.