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Controllers - Cable Assemblies

Image Part Number Description / PDF Quantity Rfq
1405060010

1405060010

Weidmuller

PAC-UNIV-FJ20-1:1 1.0M

0
8216360000

8216360000

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
998130

998130

Weidmuller

CABLE ASSEMBLY INPUT 4.9'

0
7789317050

7789317050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
998036

998036

Weidmuller

CABLE ASSEMBLY INPUT 4.9'

0
7789124020

7789124020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789291010

7789291010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789009020

7789009020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789043050

7789043050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789793050

7789793050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789002030

7789002030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
998021

998021

Weidmuller

CABLE ASSEMBLY OUTPUT 6.56'

0
7789261030

7789261030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
7789311050

7789311050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789835030

7789835030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
7789641020

7789641020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789239015

7789239015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
7789134030

7789134030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
7789118050

7789118050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789848050

7789848050

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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