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Controllers - Cable Assemblies

Image Part Number Description / PDF Quantity Rfq
7789158030

7789158030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
1512470005

1512470005

Weidmuller

PAC-PREM-2X10-V1-0M5

0
7789732015

7789732015

Weidmuller

PAC-CTLX-UNIS-V0-1.5M

0
998066

998066

Weidmuller

CABLE ASSEMBLY OUTPUT 3.28'

0
7789621010

7789621010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789285015

7789285015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
7789649010

7789649010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789654030

7789654030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
7789285010

7789285010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789329020

7789329020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789059030

7789059030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
7789637020

7789637020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789017020

7789017020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789606010

7789606010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789110030

7789110030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
7789848020

7789848020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
996158

996158

Weidmuller

CABLE ASSEMBLY OUTPUT 1.64'

0
7789019010

7789019010

Weidmuller

ABCTH 16ET 0100

0
7789015020

7789015020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789250015

7789250015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

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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