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Controllers - Cable Assemblies

Image Part Number Description / PDF Quantity Rfq
2305978

2305978

Phoenix Contact

CABLE ASSEMBLY INTERFACE 4.9'

0
2290863

2290863

Phoenix Contact

CABLE ASSEMBLY INTERFACE 19.69'

0
2304652

2304652

Phoenix Contact

CABLE ASSEMBLY INTERFACE 6.56'

0
2305787

2305787

Phoenix Contact

CABLE ASSEMBLY INTERFACE 19.69'

0
2900142

2900142

Phoenix Contact

CABLE ASSEMBLY INTERFACE 6.56'

0
2304924

2304924

Phoenix Contact

CABLE ASSEMBLY INTERFACE 13.1'

0
2294678

2294678

Phoenix Contact

CABLE ASSEMBLY INTERFACE 6.56'

0
2289667

2289667

Phoenix Contact

CABLE ASSEMBLY INTERFACE 29.5'

0
2314558

2314558

Phoenix Contact

CABLE ASSEMBLY INTERFACE 98.4'

0
2318389

2318389

Phoenix Contact

CABLE ASSEMBLY INTERFACE 1.64'

0
2299356

2299356

Phoenix Contact

CABLE ASSEMBLY INTERFACE 19.69'

0
2322553

2322553

Phoenix Contact

CABLE ASSEMBLY INTERFACE 1.64'

0
2318334

2318334

Phoenix Contact

CABLE ASSEMBLY INTERFACE 6.56'

0
2321185

2321185

Phoenix Contact

CABLE ASSEMBLY INTERFACE 3.28'

0
2305839

2305839

Phoenix Contact

CABLE ASSEMBLY INTERFACE 13.1'

0
2322757

2322757

Phoenix Contact

CABLE ASSEMBLY INTERFACE 26.25'

0
2296935

2296935

Phoenix Contact

CABLE ASSEMBLY INTERFACE 4.9'

0
2304911

2304911

Phoenix Contact

CABLE ASSEMBLY INTERFACE 9.84'

0
2299576

2299576

Phoenix Contact

CABLE ASSEMBLY INTERFACE 32.8'

0
2321156

2321156

Phoenix Contact

CABLE ASSEMBLY INTERFACE 26.25'

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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