Controllers - Cable Assemblies

Image Part Number Description / PDF Quantity Rfq
7789019010

7789019010

Weidmuller

ABCTH 16ET 0100

0

2321554

2321554

Phoenix Contact

CABLE ASSEMBLY INTERFACE 59.1'

0

7789015020

7789015020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0

7789250015

7789250015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0

2314299

2314299

Phoenix Contact

CABLE ASSEMBLY INTERFACE 6.56'

0

XW2Z-200J-B32

XW2Z-200J-B32

Omron Automation & Safety Services

CABLE ASSEMBLY INTERFACE 6.56'

0

2321091

2321091

Phoenix Contact

CABLE ASSEMBLY INTERFACE 1.64'

0

XW2Z-RO150C-125-MN

XW2Z-RO150C-125-MN

Omron Automation & Safety Services

CONNECT CABLE PLC 32-OUTPUT

0

7789609010

7789609010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0

7789026015

7789026015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0

CS1W-CN625

CS1W-CN625

Omron Automation & Safety Services

CABLE ASSY PROGRAMMING 19.69'

0

AFP85132

AFP85132

Panasonic

CABLE ASSEMBLY INTERFACE 6.56'

0

2320487

2320487

Phoenix Contact

CABLE ASSY COMMUNICATIONS 6.56'

1

7789224010

7789224010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0

7789108020

7789108020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0

7789229050

7789229050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0

7789696015

7789696015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0

2318198

2318198

Phoenix Contact

CABLE ASSEMBLY INTERFACE 19.69'

0

CBL-4C-14G-30

CBL-4C-14G-30

Red Lion

POWER CBL 4 COND 14AWG W/ 4 CRIM

0

7789308050

7789308050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

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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