Posted to News on 1st Jun 2026, 10:00
Why outdated colour conventions can now create reliability and maintenance risks in modern machinery
For many years, assigning cable function by sheath colour helped simplify installation and reduce assembly mistakes. In modern automation systems, however, that same approach can now create risk, as the experts at motec explain.
(See motec at Machine Building South, 8 July 2026, on stand 107)
DESINA was introduced to bring consistency to industrial machine design, giving engineers a standard method for identifying drives, control systems and cabling. This was effective for many years, as assigning cable function by sheath colour helped simplify installation and reduce assembly errors.
In modern automation systems, however, that same approach can now introduce risk. As machinery becomes more integrated, a single cable may carry power, feedback and communication within one assembly. Traditional DESINA colours such as orange for servo power, green for feedback and grey for control circuits no longer reliably represent full cable functionality. Different manufacturers may also interpret the standard differently, resulting in visually similar cables with significantly different electrical characteristics.
As automation platforms continue to combine motion control, sensing, safety and network communication into increasingly compact systems, engineers are having to look beyond traditional installation conventions. Reliability is now driven less by visual identification and more by system compatibility, electrical performance and long-term operational stability.
In production environments where downtime costs can escalate rapidly, correct cable specification has become as important as the active components themselves. This is particularly important during servicing and retrofit work, where engineers under time pressure may rely on colour as a quick identifier. In some cases, a replacement cable may appear correct while lacking the shielding, impedance or voltage rating required by the application. The result can be intermittent faults, drive instability or unnecessary downtime.
Sheath colour remains a useful reference, but it is never a substitute for verifying full electrical and mechanical performance data. In modern industrial systems, reliability depends on every connection performing exactly as specified.
motec will be available to answer any questions and will be exhibiting on Stand 107 at Machine Building South on 8 July at Sandown Park, Esher, Surrey KT10 9AJ. Click here for VIP registration for attendees.
