Industrial environments such as automotive, robotics, marine, and automation place immense mechanical stress on cables. These cables don’t just bend, they twist. Without the ability to withstand repeated torsion, cables are prone to premature failure, costly downtime, and even hazardous conditions. That’s why manufacturers rely on advanced testing equipment like Torsional Testers to validate the durability and reliability of their cables in real-world conditions.
What Is a Torsional Tester?
A Torsional Tester evaluates a cable’s resistance to twisting stress. Unlike bending or flexing tests, torsional testing replicates the unique mechanical forces a cable experiences when it’s twisted around its axis, motion that happens frequently in dynamic applications like robotic arms, cable reels, and other automated machinery.
How Does the Torsional Cable Tester Work?
Torsional Testers simulate real-world mechanical stress by rotating a fixed length of cable repeatedly, both clockwise and counterclockwise, under controlled axial tension.
Watch our video to see it in action and learn more from our ATPC Engineer.
Key machine features include:
- Precision-Controlled Rotation: One end of the cable is clamped and held stationary, while the opposite end is twisted through programmable angles, typically ranging from ±180° up to ±270°, depending on the application. The tester rotates the cable at variable speeds (1 to 60 RPM), allowing for simulation of different mechanical use cases.
- Programmable Test Cycles: Engineers can precisely configure testing parameters, including torsion angle, speed, tension load, and total number of cycles. This enables repeatable, standardized testing across multiple cable types and designs.
- Axial Load Control: In many testers, axial tension is applied during rotation to simulate real-world installation stress. This ensures the test replicates the combined forces of twisting and pulling that cables often face in the field.
- Real-Time Performance Monitoring: Integrated electrical continuity monitoring tracks the cable’s status during each twist. The system detects a loss of electrical continuity in real time.
- Accelerated Life Testing: The tester is capable of running thousands to millions of cycles continuously, offering a compressed timeline to evaluate long-term durability, fatigue resistance, and failure modes.
Why Torsional Testing Is Critical for Industrial Cable Applications
If your cable solution is used in any rotating or twisting application, torsional testing provides confidence that your cable won’t fail when it matters most. A Torsional Tester helps ensure:
✅ Longer Service Life: Withstand repeated twist cycles without degradation.
✅ Mechanical Integrity: Maintain conductor, insulation, and shield performance even under extreme motion.
✅ Operational Uptime: Reduce unexpected cable failures that can halt production.
✅ Regulatory & Industry Compliance: Ensure your cables meet durability requirements for mission-critical environments.
Tested to Perform—Built to Last
At Amphenol TPC Wire & Cable, we develop and test cables specifically for harsh, high-flex environments. Our Torsional Tester simulates extreme twisting conditions to help us refine cable design, validate performance, and deliver products that won’t fail under pressure.
Find Cables That Can Take the Twist
Need cables for demanding applications like automotive, mining, robotics, or automation environments? We’ve tested them to twist—and they passed. From power and control to data and hybrid cables, our solutions deliver high performance under torsion and beyond.
Contact Amphenol TPC Wire & Cable today to discover how our torsion-tested cables can enhance your operation's reliability.
Explore Industry-Leading Torsional Testing Equipment
Want to learn more about the testing equipment used to validate cable performance? Explore these trusted manufacturers of torsional testing systems:
- Sjogren Industries – Torsion Twist Tester
A programmable tester designed for evaluating metal wire durability and detecting material flaws.
- ZwickRoell – Torsion Testing Machines
High-precision torsion testers with configurable torque capacity and combined load functionality.
- Instron – Torsion Testing Systems
Offers both stand-alone and integrated systems for dual-axis (axial and torsional) testing environments.
- Tinius Olsen – High-Capacity Torsion Testers
Heavy-duty machines for high-torque industrial materials, capable of continuous or intermittent rotation.
- Torontech – Optical Fiber Cable Torsion Tester
Designed specifically for telecommunications applications and compliant with IEC testing standards.
- STEP Lab – Static and Fatigue Torsion Testing Machines
Advanced testers built for dynamic fatigue simulation and high-accuracy rotational control.
Contact us today to learn more about how our cables can enhance the reliability and efficiency of your operations.