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Controllers - Cable Assemblies

Image Part Number Description / PDF Quantity Rfq
7789059010

7789059010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789273010

7789273010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789038020

7789038020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
2318907

2318907

Phoenix Contact

CABLE ASSEMBLY INTERFACE 9.84'

0
7789041015

7789041015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
CS1W-CN131-B2

CS1W-CN131-B2

Omron Automation & Safety Services

CABLE ASSEMBLY I/O 39.4'

0
2904078

2904078

Phoenix Contact

CABLE ASSEMBLY INTERFACE 9.84'

0
XW2Z-RO200C-150-MN

XW2Z-RO200C-150-MN

Omron Automation & Safety Services

CONNECT CABLE PLC 32-OUTPUT

0
7789380015

7789380015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
2299589

2299589

Phoenix Contact

CABLE ASSEMBLY INTERFACE 19.69'

0
7789073010

7789073010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789044030

7789044030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
7789215010

7789215010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
2289638

2289638

Phoenix Contact

CABLE ASSEMBLY INTERFACE 24.6'

0
7789670050

7789670050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789011010

7789011010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789048010

7789048010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
1349900020

1349900020

Weidmuller

PAC-UNIV-HE50-F-2M

0
XW2Z-R200C-175-150

XW2Z-R200C-175-150

Omron Automation & Safety Services

CONNECT CABLE W/CONN 2M

0
7789124015

7789124015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

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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