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Controllers - Cable Assemblies

Image Part Number Description / PDF Quantity Rfq
2321444

2321444

Phoenix Contact

CABLE ASSEMBLY INTERFACE 42.65'

0
2294610

2294610

Phoenix Contact

CABLE ASSEMBLY INTERFACE 1.64'

0
2296498

2296498

Phoenix Contact

CABLE ASSEMBLY INTERFACE 9.84'

0
2321635

2321635

Phoenix Contact

CABLE ASSEMBLY INTERFACE 1.64'

0
2304319

2304319

Phoenix Contact

CABLE ASSEMBLY INTERFACE 0.984'

0
2314338

2314338

Phoenix Contact

CABLE ASSEMBLY INTERFACE 49.20'

0
2296841

2296841

Phoenix Contact

CABLE ASSEMBLY INTERFACE 9.84'

0
2322786

2322786

Phoenix Contact

CABLE ASSEMBLY INTERFACE 3.28'

0
2314383

2314383

Phoenix Contact

CABLE ASSEMBLY INTERFACE 49.20'

0
2299288

2299288

Phoenix Contact

CABLE ASSEMBLY INTERFACE 32.8'

0
2299084

2299084

Phoenix Contact

CABLE ASSEMBLY INTERFACE 5.9'

0
2302492

2302492

Phoenix Contact

CABLE ASSEMBLY INTERFACE 6.56'

0
2322456

2322456

Phoenix Contact

CABLE ASSEMBLY INTERFACE 3.28'

0
2318143

2318143

Phoenix Contact

CABLE ASSEMBLY INTERFACE 4.9'

0
2321211

2321211

Phoenix Contact

CABLE ASSEMBLY INTERFACE 13.1'

0
2298522

2298522

Phoenix Contact

CABLE ASSEMBLY INTERFACE 6.56'

0
2304348

2304348

Phoenix Contact

CABLE ASSEMBLY INTERFACE 0.984'

0
2305994

2305994

Phoenix Contact

CABLE ASSEMBLY INTERFACE 8.2'

0
2321664

2321664

Phoenix Contact

CABLE ASSEMBLY INTERFACE 9.84'

0
2296537

2296537

Phoenix Contact

CABLE ASSY COMMUNICATIONS 32.8'

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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