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Controllers - Cable Assemblies

Image Part Number Description / PDF Quantity Rfq
2305826

2305826

Phoenix Contact

CABLE ASSEMBLY INTERFACE 1.64'

0
7789677050

7789677050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789039015

7789039015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
2293899

2293899

Phoenix Contact

CABLE ASSEMBLY INTERFACE 16.4'

0
7789284015

7789284015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
2981648

2981648

Phoenix Contact

CABLE ASSEMBLY INTERFACE 8.2'

0
996644

996644

Weidmuller

CABLE ASSEMBLY INPUT 6.56'

0
XW2Z-100J-B32

XW2Z-100J-B32

Omron Automation & Safety Services

CABLE ASSEMBLY INTERFACE 3.28'

0
2304254

2304254

Phoenix Contact

CABLE ASSEMBLY INTERFACE 6.56'

0
7789677020

7789677020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789731020

7789731020

Weidmuller

PAC-CTLX-UNIU-VO-2M

0
XW2Z-200J-B7

XW2Z-200J-B7

Omron Automation & Safety Services

CABLE ASSEMBLY INTERFACE 6.56'

0
7789158020

7789158020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789076020

7789076020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
2304762

2304762

Phoenix Contact

CABLE ASSEMBLY INTERFACE 13.1'

0
XW2Z-10MJ-G9

XW2Z-10MJ-G9

Omron Automation & Safety Services

CABLE ASSEMBLY INTERFACE 32.8'

0
7789031050

7789031050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789276050

7789276050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
2321716

2321716

Phoenix Contact

CABLE ASSEMBLY INTERFACE 1.64'

0
XW2Z-500A

XW2Z-500A

Omron Automation & Safety Services

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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