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Controllers - Cable Assemblies

Image Part Number Description / PDF Quantity Rfq
998111

998111

Weidmuller

CABLE ASSEMBLY INPUT 1.64'

0
7789642050

7789642050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789276025

7789276025

Weidmuller

CABLE ASSEMBLY INTERFACE 8.2'

0
8216370000

8216370000

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789758010

7789758010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
998118

998118

Weidmuller

CABLE ASSEMBLY OUTPUT 4.9'

0
7789073015

7789073015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
7789647050

7789647050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789380010

7789380010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789316030

7789316030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
7789237030

7789237030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
7789261050

7789261050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789134010

7789134010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789373030

7789373030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
919608

919608

Weidmuller

CABLE ASSEMBLY

0
7789320030

7789320030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
7789697010

7789697010

Weidmuller

PAC-CMLX-HE20-V4-1M

0
7789883050

7789883050

Weidmuller

PAC-C300-3636-14-05

0
7789309020

7789309020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789664050

7789664050

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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