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Controllers - Cable Assemblies

Image Part Number Description / PDF Quantity Rfq
7789606020

7789606020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789195030

7789195030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
7789619050

7789619050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789042010

7789042010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789025030

7789025030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
7789650010

7789650010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789010020

7789010020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
998279

998279

Weidmuller

CABLE ASSEMBLY INPUT 6.56'

0
7789137010

7789137010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789033020

7789033020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789319020

7789319020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
919611

919611

Weidmuller

CABLE ASSEMBLY

0
7789046020

7789046020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789133015

7789133015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
8216410000

8216410000

Weidmuller

CABLE ASSEMBLY INTERFACE 13.1'

0
7789758015

7789758015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
7789678030

7789678030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
7789151015

7789151015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
7789636030

7789636030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
7789286050

7789286050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

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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