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Controllers - Cable Assemblies

Image Part Number Description / PDF Quantity Rfq
ASR-USB

ASR-USB

Altech Corporation

USB CABLE SMART RELAYPROGRAMMING

47
7789286030

7789286030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
7789030030

7789030030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
7789254050

7789254050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
2305321

2305321

Phoenix Contact

CABLE ASSEMBLY INTERFACE 6.56'

0
C200HS-CN229-EU

C200HS-CN229-EU

Omron Automation & Safety Services

CABLE ASSEMBLY INTERFACE

0
7789247020

7789247020

Weidmuller

PAC-S300-HE20-V8-2M

0
7789733010

7789733010

Weidmuller

PAC-CTLX-UNIU-V1-1M

0
7789388020

7789388020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
2305295

2305295

Phoenix Contact

CABLE ASSEMBLY INTERFACE 9.84'

0
7789026010

7789026010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789236025

7789236025

Weidmuller

CABLE ASSEMBLY INTERFACE 8.2'

0
2304144

2304144

Phoenix Contact

CABLE ASSEMBLY INTERFACE 3.28'

0
7789024020

7789024020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
2302641

2302641

Phoenix Contact

CABLE ASSEMBLY INTERFACE 1.64'

0
7789133020

7789133020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
2299259

2299259

Phoenix Contact

CABLE ASSEMBLY INTERFACE 13.1'

0
2305376

2305376

Phoenix Contact

CABLE ASSEMBLY INTERFACE 6.56'

0
7789014030

7789014030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
7789058010

7789058010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

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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