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Controllers - Cable Assemblies

Image Part Number Description / PDF Quantity Rfq
998005

998005

Weidmuller

CABLE ASSEMBLY INPUT 3.28'

0
7789842010

7789842010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789074015

7789074015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
7789835010

7789835010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789284050

7789284050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789041020

7789041020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789665015

7789665015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
7789842050

7789842050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789637010

7789637010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789261015

7789261015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
7789010050

7789010050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789018030

7789018030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
1512170035

1512170035

Weidmuller

PAC-M340-4X10-V0-3M5

0
7789653050

7789653050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789074030

7789074030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
7789771015

7789771015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
998037

998037

Weidmuller

CABLE ASSEMBLY INPUT 6.56'

0
7789110050

7789110050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789026020

7789026020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789233015

7789233015

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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