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Controllers - Cable Assemblies

Image Part Number Description / PDF Quantity Rfq
7789030020

7789030020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789382010

7789382010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789665050

7789665050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789101025

7789101025

Weidmuller

CABLE ASSEMBLY INTERFACE 8.2'

0
7789008050

7789008050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789679020

7789679020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
998029

998029

Weidmuller

CABLE ASSEMBLY OUTPUT 6.56'

0
919731

919731

Weidmuller

CABLE ASSEMBLY INPUT 1.64'

0
915809

915809

Weidmuller

CABLE ASSEMBLY INPUT 1.64'

0
7789211050

7789211050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789672015

7789672015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
7789790030

7789790030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
7789801010

7789801010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789607050

7789607050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789214030

7789214030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
7789029050

7789029050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789033010

7789033010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789736010

7789736010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
919752

919752

Weidmuller

CABLE ASSEMBLY OUTPUT 1.64'

0
998025

998025

Weidmuller

CABLE ASSEMBLY OUTPUT 6.56'

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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