Specialized Cable Assemblies

Image Part Number Description / PDF Quantity Rfq
6720000548

6720000548

Weidmuller

MS-C32B-C26M09-L8D-5.5

0

6720000683

6720000683

Weidmuller

MS-C16B-C16B-L8D-010

0

10119608-N0190YYLF

10119608-N0190YYLF

Storage & Server IO (Amphenol ICC)

501-21KF-SOFIX 2X4

0

6720001032

6720001032

Weidmuller

MS-C2+B-C6+B04-L2A-005

0

2-558057-0

2-558057-0

TE Connectivity AMP Connectors

CABLE ASSY PWR-PWR 8 WIRE 73"

0

10075923-N1500YYLF

10075923-N1500YYLF

Storage & Server IO (Amphenol ICC)

501-21ZF-METRAL HIGH MULT

0

672000102401

672000102401

Weidmuller

SP-CBL HDC 24VDC FIAT 1M

0

8-1196969-2

8-1196969-2

TE Connectivity Aerospace Defense and Marine

IN LINE COUPLERS

0

2-555858-0

2-555858-0

TE Connectivity AMP Connectors

CABLE ASSY PWR ENTRY 5 WIRE 10"

0

D-500-0255-000

D-500-0255-000

TE Connectivity Aerospace Defense and Marine

IN LINE COUPLERS

0

6720000751

6720000751

Weidmuller

MS-C32B-B26X04-L8D-012

0

6720001136

6720001136

Weidmuller

MS-C32B-FFLX03-X2D-015

0

D-500-0255-021-08

D-500-0255-021-08

TE Connectivity Aerospace Defense and Marine

IN LINE COUPLERS

0

6720000730

6720000730

Weidmuller

MS-C2+B-FFLX03-X8D-010

0

6720000830

6720000830

Weidmuller

MS-C2+B-C2+B-L8D-2.5

0

2-555858-3

2-555858-3

TE Connectivity AMP Connectors

CABLE ASSY PWR ENTRY 5 WIRE 90"

0

6483888-3

6483888-3

TE Connectivity AMP Connectors

QUICK DISCONNECT PLUG ASSY

0

20826311030

20826311030

HARTING

RJ INDUSTRIAL PRELINK CAT5 PATCH

0

6720000894

6720000894

Weidmuller

MS-C32B-RFLX09-X8D-5.5

0

2-558057-8

2-558057-8

TE Connectivity AMP Connectors

CABLE ASSY PWR-PWR 8 WIRE 82"

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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