Controllers - Cable Assemblies

Image Part Number Description / PDF Quantity Rfq
996424

996424

Weidmuller

CABLE ASSEMBLY OUTPUT 4.9'

0

XW2Z-RO200C-175-MN

XW2Z-RO200C-175-MN

Omron Automation & Safety Services

CONNECT CABLE PLC 32-OUTPUT

0

7789673020

7789673020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0

2296935

2296935

Phoenix Contact

CABLE ASSEMBLY INTERFACE 4.9'

0

7789190015

7789190015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0

2304911

2304911

Phoenix Contact

CABLE ASSEMBLY INTERFACE 9.84'

0

7789384030

7789384030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0

7789234030

7789234030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0

7789229025

7789229025

Weidmuller

CABLE ASSEMBLY INTERFACE 8.2'

0

7789636020

7789636020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0

7789046050

7789046050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0

7789301010

7789301010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0

7789626030

7789626030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0

7789011015

7789011015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0

XW2Z-RI75-50-D1

XW2Z-RI75-50-D1

Omron Automation & Safety Services

CONNECT CABLE PLC 32-INPUT

0

7789191050

7789191050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0

7789137020

7789137020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0

2299576

2299576

Phoenix Contact

CABLE ASSEMBLY INTERFACE 32.8'

0

7789239050

7789239050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0

2321156

2321156

Phoenix Contact

CABLE ASSEMBLY INTERFACE 26.25'

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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