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Controllers - Cable Assemblies

Image Part Number Description / PDF Quantity Rfq
7789073030

7789073030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
7789210050

7789210050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789015010

7789015010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789041050

7789041050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
998058

998058

Weidmuller

CABLE ASSEMBLY OUTPUT 4.9'

0
7789626015

7789626015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
7789031025

7789031025

Weidmuller

CABLE ASSEMBLY INTERFACE 8.2'

0
7789768010

7789768010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789003010

7789003010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
1373700015

1373700015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
998004

998004

Weidmuller

CABLE ASSEMBLY INPUT 1.64'

0
7789291030

7789291030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
7789106015

7789106015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
7789642015

7789642015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
7789301015

7789301015

Weidmuller

PAC-UNIV-HE20-1:1-1.5M

0
7789288050

7789288050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789063050

7789063050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789633015

7789633015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
7789033030

7789033030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
7789328050

7789328050

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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