Circular Cable Assemblies

Part Number	Description / PDF	Quantity
10-02472 Tensility International Corporation	CBL FMALE TO WIRE LEAD 5P 6'	100
10-03869 Tensility International Corporation	CABLE M5 3POS M LEADS 6' SHIELD	0
10-00423 Tensility International Corporation	CBL MALE TO WIRE LEAD 7POS 6'	204
10-03011 Tensility International Corporation	CBL ASSEMBLY 3POS M TO WIRE 6'	379
10-03823 Tensility International Corporation	CBL ASSY M12 A 3POS F-WIRE 5M	0
10-03635 Tensility International Corporation	CBL ASSY 4POS F TO WIRE SHD 6'	430
10-03010 Tensility International Corporation	CBL ASSY 3POS FEMALE TO F SHD 6'	125
10-00538 Tensility International Corporation	CBL FMALE RA TO WIRE 13POS 6'	113
10-02266 Tensility International Corporation	CBL MALE TO WIRE LEAD 7POS 6'	81
10-03818 Tensility International Corporation	CBL ASSY M12 A 8POS M-WIRE 3M	0
10-02262 Tensility International Corporation	CBL MALE TO WIRE LEAD 5POS 6'	98
10-03846 Tensility International Corporation	CBL ASSY M12 A 4POS M-F 3M	0
10-00432 Tensility International Corporation	CBL FMALE TO WIRE LEAD 9P 6'	102
10-03013 Tensility International Corporation	CBL ASSY 4POS FEMALE TO F SHD 6'	362
10-00549 Tensility International Corporation	CBL FMALE RA TO WIRE 6POS 6'	7
10-00439 Tensility International Corporation	CBL MALE TO WIRE LEAD 13P 6'	190
10-03842 Tensility International Corporation	CBL ASSY M12 A 3POS M-F 3M	0
10-02263 Tensility International Corporation	CBL MALE TO MALE 5POS SHLD 6'	100
10-03827 Tensility International Corporation	CBL ASSY M12 A 4POS F-WIRE 5M	0
10-03820 Tensility International Corporation	CBL ASSY M12 A 8POS M-WIRE 10M	0

Circular Cable Assemblies

1. Overview

Circular Cable Assemblies are engineered interconnect solutions designed to transmit electrical signals or power through circular-shaped connectors. These assemblies combine multiple wires or cables terminated with circular connectors, ensuring reliable connectivity in demanding environments. Their importance spans across industries requiring robust, high-density, and high-performance connections, particularly in applications where space constraints and environmental resilience are critical.

2. Main Types and Functional Classification

Type	Functional Features	Application Examples
Circular Push-Pull	Quick-mating design with mechanical locking	Industrial automation, medical devices
Circular Threaded	Vibration-resistant threaded coupling	Aerospace, military equipment
Waterproof Circular	IP67+ sealing against liquids and dust	Outdoor telecom equipment, underwater sensors
High-Density Circular	Miniaturized contacts for compact designs	Avionics, robotics

3. Structure and Components

A typical circular cable assembly consists of:

Conductors: Copper/aluminum for signal/power transmission
Insulation: PVC/TPE/PUR jackets for dielectric protection
Shielding: Braided copper or foil for EMI/RFI protection
Connector Housing: Metal/plastic shells with precision contacts
Retention System: Latches, threads, or bayonet couplings

Modular designs allow customization with hybrid signal/power/RF configurations.

4. Key Technical Specifications

Parameter	Importance
Current Rating (Amps)	Determines power transmission capacity
Voltage Rating (Volts)	Defines dielectric strength and safety margins
Contact Resistance (m )	Impacts signal integrity and power efficiency
Operating Temperature (-40 C to +125 C)	Ensures reliability in extreme environments
Mating Cycles (1000-10,000)	Indicates mechanical durability
IP Rating (IP65-IP68)	Defines environmental protection level

5. Application Fields

Primary industries include:

Industrial Automation: PLCs, CNC machines, robotic arms
Telecommunications: 5G base stations, fiber optic enclosures
Medical Equipment: MRI scanners, patient monitoring systems
Aerospace: Avionics, flight control systems
Transportation: Rail signaling systems, EV charging stations

Case Study: In automotive manufacturing, circular assemblies enable high-vibration resistance connections in robotic welding cells operating 24/7.

6. Leading Manufacturers and Products

Manufacturer	Representative Product
TE Connectivity	DEUTSCH DT Series circular connectors
Amphenol	CIRCULAR C Series high-density connectors
Molex	Circular Rast 55 series for industrial control
Delphi	Weatherproof automotive circular connectors

7. Selection Guidelines

Key considerations:

Electrical requirements (current/voltage profiles)
Environmental conditions (temperature, moisture, chemical exposure)
Mechanical demands (vibration, mating cycles, cable bend radius)
Space constraints (connector size and orientation)
Industry-specific certifications (e.g., MIL-STD, UL, RoHS)

Recommend verifying compatibility with existing infrastructure and performing thermal cycling tests for critical applications.

8. Industry Trends

Emerging developments include:

Miniaturization while maintaining high contact density
Integration of fiber optics and high-speed data transmission
Adoption of composite materials for weight reduction
Growing demand for waterproof connectors in outdoor IoT deployments
Standardization of hybrid power/signal interfaces in EV charging

Market forecasts predict 8.2% CAGR through 2027 driven by industrial IoT and 5G infrastructure investments.