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Controllers - Cable Assemblies

Image Part Number Description / PDF Quantity Rfq
7789678020

7789678020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789075030

7789075030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
7789312020

7789312020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789063010

7789063010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789842015

7789842015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
7789126010

7789126010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789061010

7789061010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

0
7789064020

7789064020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789646015

7789646015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
998090

998090

Weidmuller

CABLE ASSEMBLY OUTPUT 1.64'

0
7789673050

7789673050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789652030

7789652030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
7789652050

7789652050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789064050

7789064050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
7789195020

7789195020

Weidmuller

CABLE ASSEMBLY INTERFACE 6.56'

0
7789119015

7789119015

Weidmuller

CABLE ASSEMBLY INTERFACE 4.9'

0
7789319030

7789319030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
7789648050

7789648050

Weidmuller

CABLE ASSEMBLY INTERFACE 16.4'

0
1350250030

1350250030

Weidmuller

CABLE ASSEMBLY INTERFACE 9.84'

0
7789066010

7789066010

Weidmuller

CABLE ASSEMBLY INTERFACE 3.28'

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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