Controllers - Cable Assemblies

Image Part Number Description / PDF Quantity Rfq
XW2Z-200K

XW2Z-200K

Omron Automation & Safety Services

CABLE ASSEMBLY INTERFACE 6.56'

0

7789619015

7789619015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0

2318389

2318389

Phoenix Contact

CABLE ASSEMBLY INTERFACE 1.64'

0

XW2Z-R500C-475-450

XW2Z-R500C-475-450

Omron Automation & Safety Services

CONNECT CABLE W/CONN 5M

0

7789032015

7789032015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0

7789664015

7789664015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0

2299356

2299356

Phoenix Contact

CABLE ASSEMBLY INTERFACE 19.69'

0

7789622015

7789622015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0

7789136015

7789136015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0

7789046030

7789046030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0

7789732020

7789732020

Weidmuller

PAC-CTLX-UNIS-VO-2M

0

7789278010

7789278010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0

7789038015

7789038015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0

7789642010

7789642010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0

915802

915802

Weidmuller

CABLE ASSEMBLY INPUT 1.64'

0

7789191015

7789191015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0

2322553

2322553

Phoenix Contact

CABLE ASSEMBLY INTERFACE 1.64'

0

7789239010

7789239010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0

2318334

2318334

Phoenix Contact

CABLE ASSEMBLY INTERFACE 6.56'

0

2321185

2321185

Phoenix Contact

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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