Controllers - Cable Assemblies

Image Part Number Description / PDF Quantity Rfq
7789630010

7789630010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0

2290863

2290863

Phoenix Contact

CABLE ASSEMBLY INTERFACE 19.69'

0

2304652

2304652

Phoenix Contact

CABLE ASSEMBLY INTERFACE 6.56'

0

2305787

2305787

Phoenix Contact

CABLE ASSEMBLY INTERFACE 19.69'

0

7789651015

7789651015

Weidmuller

PAC-CJ1W-HE20-V6-1.5M

0

7789835015

7789835015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0

2900142

2900142

Phoenix Contact

CABLE ASSEMBLY INTERFACE 6.56'

0

P2RV-A200C

P2RV-A200C

Omron Automation & Safety Services

CABLE ASSEMBLY INTERFACE 6.56'

0

XW2Z-100H-3

XW2Z-100H-3

Omron Automation & Safety Services

CABLE ASSEMBLY I/O 3.28'

0

2304924

2304924

Phoenix Contact

CABLE ASSEMBLY INTERFACE 13.1'

0

998065

998065

Weidmuller

CABLE ASSEMBLY OUTPUT 1.64'

0

7789194020

7789194020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0

7789049050

7789049050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0

7789650015

7789650015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0

7789641030

7789641030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0

XW2Z-050J-A30

XW2Z-050J-A30

Omron Automation & Safety Services

CABLE ASSEMBLY INTERFACE 1.64'

0

7789259050

7789259050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0

7789106020

7789106020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0

996641

996641

Weidmuller

CABLE ASSEMBLY INPUT 1.64'

0

7789237050

7789237050

Weidmuller

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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