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Controllers - Cable Assemblies

Image Part Number Description / PDF Quantity Rfq
2299589

2299589

Phoenix Contact

CABLE ASSEMBLY INTERFACE 19.69'

0
2289638

2289638

Phoenix Contact

CABLE ASSEMBLY INTERFACE 24.6'

0
2900132

2900132

Phoenix Contact

CABLE ASSEMBLY INTERFACE 4.9'

142
2302670

2302670

Phoenix Contact

CABLE ASSEMBLY INTERFACE 9.84'

0
2318871

2318871

Phoenix Contact

CABLE ASSEMBLY INTERFACE 3.28'

0
2304872

2304872

Phoenix Contact

CABLE ASSEMBLY INTERFACE 1.64'

0
2290847

2290847

Phoenix Contact

CABLE ASSEMBLY INTERFACE 14.76'

0
2903395

2903395

Phoenix Contact

CABLE ASSEMBLY INTERFACE 3.28'

0
2321389

2321389

Phoenix Contact

CABLE ASSEMBLY INTERFACE 36.1'

0
2321596

2321596

Phoenix Contact

CABLE ASSEMBLY INTERFACE 52.5'

0
2321017

2321017

Phoenix Contact

CABLE ASSEMBLY INTERFACE 1.64'

0
2314927

2314927

Phoenix Contact

CABLE ASSEMBLY INTERFACE 19.69'

0
2302489

2302489

Phoenix Contact

CABLE ASSEMBLY INTERFACE 3.28'

0
2900144

2900144

Phoenix Contact

CABLE ASSEMBLY INTERFACE 13.1'

0
2318091

2318091

Phoenix Contact

CABLE ASSEMBLY INTERFACE 13.1'

0
2318127

2318127

Phoenix Contact

CABLE ASSEMBLY INTERFACE 1.64'

0
2314312

2314312

Phoenix Contact

CABLE ASSEMBLY INTERFACE 13.1'

0
2321648

2321648

Phoenix Contact

CABLE ASSEMBLY INTERFACE 3.28'

0
2304403

2304403

Phoenix Contact

CABLE ASSEMBLY INTERFACE 9.84'

0
2295729

2295729

Phoenix Contact

CABLE ASSEMBLY INTERFACE 0.984'

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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