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Controllers - Cable Assemblies

Image Part Number Description / PDF Quantity Rfq
7789285020

7789285020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789236030

7789236030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
7789370030

7789370030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
7789630015

7789630015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
7789196030

7789196030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
7789386020

7789386020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789155020

7789155020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
915815

915815

Weidmuller

CABLE ASSEMBLY INPUT 6.56'

0
7789010010

7789010010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789044010

7789044010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789009015

7789009015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
7789315050

7789315050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789620050

7789620050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789672050

7789672050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
998187

998187

Weidmuller

CABLE ASSEMBLY INPUT 4.9'

0
7789154015

7789154015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
7789653015

7789653015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
7789623010

7789623010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789135015

7789135015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
8433310200

8433310200

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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