Controllers - Cable Assemblies

Image Part Number Description / PDF Quantity Rfq
XW2Z-150EE

XW2Z-150EE

Omron Automation & Safety Services

CABLE ASSEMBLY I/O 4.9'

0

7789632015

7789632015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0

7789679050

7789679050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0

7789220015

7789220015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0

7789759020

7789759020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0

2295729

2295729

Phoenix Contact

CABLE ASSEMBLY INTERFACE 0.984'

0

2321321

2321321

Phoenix Contact

CABLE ASSEMBLY INTERFACE 32.8'

0

CBL-4C-14G-25

CBL-4C-14G-25

Red Lion

POWER CBL 4 COND 14AWG W/ 4 CRIM

0

7789252030

7789252030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0

7789610020

7789610020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0

7789290010

7789290010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0

7789293030

7789293030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0

7789273020

7789273020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0

2318570

2318570

Phoenix Contact

CABLE ASSEMBLY INTERFACE 6.56'

0

7789628015

7789628015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0

7789655020

7789655020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0

7789646020

7789646020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0

7789257010

7789257010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0

8335900250

8335900250

Weidmuller

CABLE ASSEMBLY INTERFACE 8.2'

0

2322595

2322595

Phoenix Contact

CABLE ASSEMBLY INTERFACE 9.84'

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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