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Controllers - Cable Assemblies

Image Part Number Description / PDF Quantity Rfq
7789384010

7789384010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789798010

7789798010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789669010

7789669010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
2294678

2294678

Phoenix Contact

CABLE ASSEMBLY INTERFACE 6.56'

0
996607

996607

Weidmuller

CABLE ASSEMBLY INTERFACE 8.2'

0
7789028030

7789028030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
2289667

2289667

Phoenix Contact

CABLE ASSEMBLY INTERFACE 29.5'

0
7789262015

7789262015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
7789018010

7789018010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
XW2Z-RO50-25-D1

XW2Z-RO50-25-D1

Omron Automation & Safety Services

CONNECT CABLE PLC 32-OUTPUT

0
7789225020

7789225020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789157030

7789157030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
998265

998265

Weidmuller

CABLE ASSEMBLY

0
7789019050

7789019050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
2314558

2314558

Phoenix Contact

CABLE ASSEMBLY INTERFACE 98.4'

0
7789110010

7789110010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789046015

7789046015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
7789222050

7789222050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789382015

7789382015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
7789158015

7789158015

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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