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Controllers - Cable Assemblies

Image Part Number Description / PDF Quantity Rfq
7789076010

7789076010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
XW2Z-500J-G12

XW2Z-500J-G12

Omron Automation & Safety Services

CABLE ASSEMBLY INTERFACE 16.4'

0
2321075

2321075

Phoenix Contact

CABLE ASSEMBLY INTERFACE 26.25'

0
7789034050

7789034050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789190010

7789190010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789234015

7789234015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
7789329010

7789329010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789624030

7789624030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
7789235015

7789235015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
998125

998125

Weidmuller

CABLE ASSEMBLY OUTPUT 4.9'

0
7789388030

7789388030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
7789676020

7789676020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789313030

7789313030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
2299071

2299071

Phoenix Contact

CABLE ASSEMBLY INTERFACE 3.94'

0
2321538

2321538

Phoenix Contact

CABLE ASSEMBLY INTERFACE 52.5'

0
2305282

2305282

Phoenix Contact

CABLE ASSEMBLY INTERFACE 8.2'

0
2322731

2322731

Phoenix Contact

CABLE ASSEMBLY INTERFACE 19.69'

0
2305981

2305981

Phoenix Contact

CABLE ASSEMBLY INTERFACE 6.56'

0
7789026030

7789026030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
2322692

2322692

Phoenix Contact

CABLE ASSEMBLY INTERFACE 8.2'

0

Controllers - Cable Assemblies

1. Overview

Controller cable assemblies are pre-assembled wiring systems designed to connect industrial controllers (e.g., PLCs, HMIs, and drives) to sensors, actuators, and other equipment. They ensure reliable transmission of electrical power, signals, and data in complex automation systems. These assemblies are critical for maintaining operational efficiency, reducing downtime, and enabling scalable industrial solutions in sectors like manufacturing, energy, and transportation.

2. Main Types and Functional Classification

TypeFunctional FeaturesApplication Examples
Power CablesHigh current capacity, durable insulation for electrical power transmissionMotors, pumps, compressors
Signal CablesLow-voltage transmission, noise-resistant for data integritySensors, encoders, proximity switches
Shielded CablesEMI/RFI protection via metallic shielding layersPLCs, CNC machines, robotic arms
Industrial Ethernet CablesHigh-speed data transfer, protocols like PROFINET or EtherCATNetworked automation systems, IIoT devices

3. Structure and Components

A typical cable assembly comprises:

  • Conductors: Annealed copper or aluminum for conductivity
  • Insulation: Thermoplastic (PVC), cross-linked polyethylene (XLPE) for dielectric strength
  • Shielding: Braided copper, foil, or served tape to block interference
  • Jacket: Flame-retardant, abrasion-resistant materials (e.g., PUR, TPE)
  • Connectors: M12, RJ45, or custom interfaces with IP ratings (e.g., IP67)

4. Key Technical Specifications

ParameterImportance
Conductor Cross-Section (mm )Determines current-carrying capacity
Shielding Efficiency (dB)Measures EMI/RFI noise reduction
Temperature Range (-40 C to +125 C)Defines operational stability in harsh environments
Bending Cycle LifespanIndicates durability in dynamic applications
Voltage Rating (300V/500V/1000V)Ensures electrical safety compliance

5. Application Fields

Major industries include:

  • Manufacturing (CNC machines, conveyor belts)
  • Energy (wind turbines, grid automation)
  • Automotive (robotic welding cells, assembly lines)
  • Food & Beverage (washdown-resistant cables for hygiene zones)

6. Leading Manufacturers and Products

ManufacturerRepresentative Product
TE ConnectivityMULTI-CON Industrial Cable Assemblies
Phoenix ContactUC-POWER and UC-SIGNAL series
MolexBrad Industrial Ethernet Cables
LEONI AGCustomized hybrid power-data cables

7. Selection Guidelines

Key considerations:

  • Environmental factors: Temperature, humidity, exposure to oils/chemicals
  • Electrical demands: Voltage, current, frequency
  • Mechanical stress: Flexing, torsion, bending radius
  • Standards compliance: UL, CE, IEC 62282
  • Cost-efficiency: Balancing performance and budget

Case Study: In automotive paint shops, solvent-resistant cables with IP69K ratings are preferred for robotic arms to withstand chemical exposure and high-pressure cleaning.

8. Industry Trends

Emerging trends include:

  • Miniaturization for space-constrained applications
  • Integration of fiber optics for 10Gbps+ industrial networks
  • Smart cables with embedded sensors for predictive maintenance
  • Growing adoption of halogen-free, recyclable materials
  • Hybrid cables combining power, data, and fiber optics
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