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Controllers - Cable Assemblies

Image Part Number Description / PDF Quantity Rfq
7789018015

7789018015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
7789675050

7789675050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
996422

996422

Weidmuller

CABLE ASSEMBLY OUTPUT 1.64'

0
7789645020

7789645020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789246050

7789246050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789307030

7789307030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
7789316020

7789316020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789152050

7789152050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789625020

7789625020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789033050

7789033050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789036050

7789036050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789835020

7789835020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789037020

7789037020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789642030

7789642030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
7789293010

7789293010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789638020

7789638020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
998145

998145

Weidmuller

CABLE ASSEMBLY OUTPUT 4.9'

0
7789771010

7789771010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789113030

7789113030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
998143

998143

Weidmuller

CABLE ASSEMBLY OUTPUT 1.64'

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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