Specialized Cable Assemblies

Image Part Number Description / PDF Quantity Rfq
D-500-0457-3-613-120

D-500-0457-3-613-120

TE Connectivity Aerospace Defense and Marine

IN LINE COUPLERS

0

6720000465

6720000465

Weidmuller

MS-C2+B-C2+B-L8D-015

0

2-555858-1

2-555858-1

TE Connectivity AMP Connectors

CABLE ASSY PWR ENTRY 5 WIRE 71"

0

2137417-1

2137417-1

TE Connectivity AMP Connectors

TE CONN 2137417-1

0

6720001048

6720001048

Weidmuller

MS-C32B-C26B04-R2A-015

0

20826302030

20826302030

HARTING

PRELINK CABLE PN CAT.5 4P 3M

0

6720000859

6720000859

Weidmuller

MS-C32B-FFLX04-X8D-007

0

6720000604

6720000604

Weidmuller

MS-C32T-B26X04-L8D-005

0

6720000889

6720000889

Weidmuller

MS-C32B-RFLX09-X8D-003

0

6720000853

6720000853

Weidmuller

MS-C32B-C26B03-L2A-005

0

2-556731-5

2-556731-5

TE Connectivity AMP Connectors

CABLE ASSY PWR-LINE 8 WIRE 120"

0

1116113-3

1116113-3

TE Connectivity AMP Connectors

CABLE ASSY PWR-LINE 3 WIRE 72"

0

2137378-1

2137378-1

TE Connectivity AMP Connectors

TE CONN 2137378-1

0

10142428-N2000YYLF

10142428-N2000YYLF

Storage & Server IO (Amphenol ICC)

501-21MF-SOFIX HIGH MULT

0

6720000858

6720000858

Weidmuller

MS-C32B-FFLX04-X8D-005

0

1-558057-4

1-558057-4

TE Connectivity AMP Connectors

CABLE ASSY PWR-PWR 8 WIRE 71"

0

3-1987376-3

3-1987376-3

TE Connectivity AMP Connectors

PHOTOVOLTAIK CABLE ASSEMBLY

0

1350120350

1350120350

Weidmuller

SYSTEM CABLE, PUSHPULL POWER, PU

0

10119608-N0800YYLF

10119608-N0800YYLF

Storage & Server IO (Amphenol ICC)

501-21KF-SOFIX 2X4

0

6720000632

6720000632

Weidmuller

MS-C32T-C26M04-L8D-1.5

0

Specialized Cable Assemblies

1. Overview

Specialized Cable Assemblies are engineered interconnect solutions designed for specific performance requirements in demanding environments. These assemblies combine multiple cables, connectors, and shielding components into customized configurations to ensure reliable signal transmission, power delivery, or data integrity. Their importance spans across industries requiring precision, durability, and compliance with stringent standards, such as aerospace, medical, and industrial automation sectors.

2. Main Types and Functional Classification

TypeFunctional CharacteristicsApplication Examples
High-Temperature CablesRated for continuous operation above 150 C, using materials like PTFE or silicone rubberAerospace engine sensors, industrial ovens
EMI-Shielded AssembliesMulti-layer shielding (braided copper, foil) to block electromagnetic interferenceMilitary communication systems, MRI machines
Flexible Robotic CablesHigh-flex materials with torsion resistance for dynamic motion applicationsIndustrial robots, automated guided vehicles
High-Speed Data CablesControlled impedance (100-150 ) for signal integrity up to 40GbpsData centers, 5G base stations
Submersible CablesHermetically sealed connectors and waterproof jackets for underwater deploymentOffshore oil rigs, underwater drones

3. Structure and Components

A typical specialized cable assembly consists of:

  • Conductors: Annealed copper or aluminum with plating (tin, silver) for conductivity
  • Insulation: Materials like XLPE, FEP, or TPU based on temperature/dielectric needs
  • Shielding: Combination of braided copper, aluminum mylar tape, and drain wires
  • Jacket: Abrasion-resistant thermoplastic elastomers (TPE) or halogen-free compounds
  • Connectors: Custom-molded interfaces with locking mechanisms (e.g., MIL-DTL-38999, USB 3.1)

4. Key Technical Specifications

ParameterImportance
Conductor MaterialDetermines conductivity (60-100% IACS) and corrosion resistance
Insulation ResistanceMust exceed 100M to prevent leakage currents
Operating TemperatureDefines functional range (-65 C to +250 C typical)
Voltage RatingSafety margin for dielectric breakdown prevention
Bend RadiusMinimum curvature to avoid mechanical failure (3 OD standard)
Insertion LossCritical for high-frequency signal integrity ( 0.5dB@10GHz)

5. Application Fields

  • Aerospace: Flight control systems, avionics, and satellite communication
  • Medical: Diagnostic imaging equipment (CT/MRI), surgical robots
  • Automotive: EV battery management systems, ADAS sensors
  • Energy: Wind turbine pitch control, oil rig monitoring systems

Case Study: A subsea oil exploration project utilized 10km-length specialized assemblies with polyurethane jackets, achieving 10-year deployment without degradation at 3000m depth.

6. Leading Manufacturers and Products

ManufacturerRepresentative Product
Amphenol IndustrialMaxGuard High-Temp Cable (200 C rating)
TE ConnectivityMATE-AXAL High-Speed Automotive Cable
SamtecQSH-DP High-Density Flex Assembly
LEONI AGROBUSTEC Robotic Cable Series

7. Selection Guidelines

Key considerations include:

  • Environmental factors (temperature, chemicals, mechanical stress)
  • Signal/power requirements (frequency, voltage, current capacity)
  • Regulatory certifications (UL, RoHS, MIL-STD)
  • Cost vs. longevity trade-offs for high-reliability applications

8. Industry Trends

Emerging developments include:

  • Adoption of hybrid cables integrating fiber optics and power conductors
  • Nanocoatings for enhanced EMI protection and corrosion resistance
  • AI-driven predictive maintenance through embedded sensor cables
  • Increased demand for halogen-free materials meeting IEC 62591 standards
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