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Controllers - Cable Assemblies

Image Part Number Description / PDF Quantity Rfq
7789156015

7789156015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
7789771020

7789771020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
1373690020

1373690020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789066015

7789066015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
7789252020

7789252020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789848015

7789848015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
7789383010

7789383010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789322015

7789322015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
7789664020

7789664020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789036015

7789036015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
7789025010

7789025010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789850010

7789850010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
998092

998092

Weidmuller

CABLE ASSEMBLY OUTPUT 4.9'

0
7789237020

7789237020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789657030

7789657030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
7789119030

7789119030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
7789002015

7789002015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
7789607020

7789607020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789014010

7789014010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789655015

7789655015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

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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