Controllers - Cable Assemblies

Image Part Number Description / PDF Quantity Rfq
998022

998022

Weidmuller

CABLE ASSEMBLY OUTPUT 1.64'

0

7789793030

7789793030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0

CS1W-CN131

CS1W-CN131

Omron Automation & Safety Services

CABLE ASSEMBLY I/O 32.8'

0

998020

998020

Weidmuller

CABLE ASSEMBLY OUTPUT 4.9'

0

7789158050

7789158050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0

7789838050

7789838050

Weidmuller

C300-32B-320B-2S-M50-05

0

7789059050

7789059050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0

998024

998024

Weidmuller

CABLE ASSEMBLY OUTPUT 4.9'

0

XW2Z-100J-A13

XW2Z-100J-A13

Omron Automation & Safety Services

CABLE ASSEMBLY INTERFACE 3.28'

0

7789048050

7789048050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0

7789270010

7789270010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0

7789373020

7789373020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0

7789306050

7789306050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0

7789676050

7789676050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0

7789384015

7789384015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0

2304678

2304678

Phoenix Contact

CABLE ASSEMBLY INTERFACE 16.4'

0

NT2S-CN222-V1

NT2S-CN222-V1

Omron Automation & Safety Services

CABLE ASSEMBLY INTERFACE 6.56'

0

XW2Z-010H-1

XW2Z-010H-1

Omron Automation & Safety Services

CABLE ASSEMBLY I/O 32.8'

0

7789849050

7789849050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0

7789227015

7789227015

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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