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Controllers - Cable Assemblies

Image Part Number Description / PDF Quantity Rfq
7789801015

7789801015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
7789137015

7789137015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
7789606030

7789606030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
7789190050

7789190050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789307050

7789307050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789326050

7789326050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789330010

7789330010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789850020

7789850020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789317020

7789317020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789011050

7789011050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
919754

919754

Weidmuller

CABLE ASSEMBLY OUTPUT 4.9'

0
915816

915816

Weidmuller

CABLE ASSEMBLY OUTPUT 1.64'

0
7789380030

7789380030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
7789215020

7789215020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789321050

7789321050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789227010

7789227010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789003020

7789003020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789059015

7789059015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
7789758030

7789758030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
1373720010

1373720010

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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