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Controllers - Cable Assemblies

Image Part Number Description / PDF Quantity Rfq
7789254010

7789254010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
1360880020

1360880020

Weidmuller

CQM1 18P / H0.25-10 2.0M

0
7789301030

7789301030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
7789731010

7789731010

Weidmuller

PAC-CTLX-UNIU-VO-1M

0
7789002050

7789002050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789035050

7789035050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789044015

7789044015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
7789371020

7789371020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789136020

7789136020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789798020

7789798020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789371050

7789371050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789793015

7789793015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
7789214050

7789214050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789626020

7789626020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789136050

7789136050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789620020

7789620020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789671010

7789671010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789259015

7789259015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
7789125020

7789125020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
8235380000

8235380000

Weidmuller

CABLE ASSEMBLY INTERFACE 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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