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Controllers - Cable Assemblies

Image Part Number Description / PDF Quantity Rfq
2305279

2305279

Phoenix Contact

CABLE ASSEMBLY INTERFACE 6.56'

0
2400127

2400127

Phoenix Contact

CABLE ASSEMBLY COMMUNICATIONS

3
2904753

2904753

Phoenix Contact

CABLE ASSEMBLY INTERFACE 26.25'

0
2289036

2289036

Phoenix Contact

CABLE ASSEMBLY INTERFACE 9.84'

0
2903469

2903469

Phoenix Contact

CABLE ASSEMBLY INTERFACE 3.28'

0
2299518

2299518

Phoenix Contact

CABLE ASSEMBLY INTERFACE 9.84'

2
2299547

2299547

Phoenix Contact

CABLE ASSEMBLY INTERFACE 26.25'

0
2304542

2304542

Phoenix Contact

CABLE ASSEMBLY INTERFACE 3.28'

5
2903481

2903481

Phoenix Contact

CABLE ASSEMBLY INTERFACE 19.69'

0
2299385

2299385

Phoenix Contact

CABLE ASSEMBLY INTERFACE 1.64'

0
2298438

2298438

Phoenix Contact

CABLE ASSEMBLY INTERFACE 6.56'

0
2304555

2304555

Phoenix Contact

CABLE ASSEMBLY INTERFACE 6.56'

0
2299301

2299301

Phoenix Contact

CABLE ASSEMBLY INTERFACE 3.28'

6
2296485

2296485

Phoenix Contact

CABLE ASSEMBLY INTERFACE 6.56'

5
2903502

2903502

Phoenix Contact

CABLE ASSEMBLY INTERFACE 1.64'

0
2903472

2903472

Phoenix Contact

CABLE ASSEMBLY INTERFACE 13.1'

0
2289007

2289007

Phoenix Contact

CABLE ASSEMBLY INTERFACE 4.9'

22
2904647

2904647

Phoenix Contact

CABLE ASSEMBLY INTERFACE 49.21'

0
2904745

2904745

Phoenix Contact

CABLE ASSEMBLY INTERFACE 26.25'

0
2904417

2904417

Phoenix Contact

CABLE ASSEMBLY INTERFACE 52.5'

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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