Controllers - Cable Assemblies

Image Part Number Description / PDF Quantity Rfq
7789736100

7789736100

Weidmuller

CABLE ASSEMBLY INTERFACE 32.8'

0

NT31C-CN520-EU

NT31C-CN520-EU

Omron Automation & Safety Services

CABLE ASSEMBLY INTERFACE 16.4'

0

7789254015

7789254015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0

XW2Z-200J-B28

XW2Z-200J-B28

Omron Automation & Safety Services

CABLE ASSEMBLY INTERFACE 6.56'

0

7789310050

7789310050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0

XW2Z-100D

XW2Z-100D

Omron Automation & Safety Services

CABLE ASSEMBLY INTERFACE 3.28'

0

7789230030

7789230030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0

2305839

2305839

Phoenix Contact

CABLE ASSEMBLY INTERFACE 13.1'

0

XW2Z-R500C

XW2Z-R500C

Omron Automation & Safety Services

CONNECT CABLE W/CONN 5M

0

998095

998095

Weidmuller

CABLE ASSEMBLY

0

7789288015

7789288015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0

2322757

2322757

Phoenix Contact

CABLE ASSEMBLY INTERFACE 26.25'

0

7789370015

7789370015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0

7789195015

7789195015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0

XW2Z-500B

XW2Z-500B

Omron Automation & Safety Services

CABLE ASSEMBLY INTERFACE 16.4'

0

7789769010

7789769010

Weidmuller

PAC-CMLX-HE20-V5-1M

0

XW2Z-500H-1

XW2Z-500H-1

Omron Automation & Safety Services

CABLE ASSEMBLY I/O 16.4'

0

7789262010

7789262010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0

7789036030

7789036030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0

7789276010

7789276010

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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