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Controllers - Cable Assemblies

Image Part Number Description / PDF Quantity Rfq
2293815

2293815

Phoenix Contact

CABLE ASSEMBLY INTERFACE 1.64'

0
2321169

2321169

Phoenix Contact

CABLE ASSEMBLY INTERFACE 32.8'

0
2321677

2321677

Phoenix Contact

CABLE ASSEMBLY INTERFACE 13.1'

0
2322760

2322760

Phoenix Contact

CABLE ASSEMBLY INTERFACE 32.8'

0
2296757

2296757

Phoenix Contact

CABLE ASSEMBLY INTERFACE 26.25'

0
2296951

2296951

Phoenix Contact

CABLE ASSEMBLY INTERFACE 8.2'

0
2321745

2321745

Phoenix Contact

CABLE ASSEMBLY INTERFACE 9.84'

0
2300588

2300588

Phoenix Contact

CABLE ASSEMBLY INTERFACE 6.56'

4
2293873

2293873

Phoenix Contact

CABLE ASSEMBLY INTERFACE 11.5'

0
2321363

2321363

Phoenix Contact

CABLE ASSEMBLY INTERFACE 49.20'

0
2322744

2322744

Phoenix Contact

CABLE ASSEMBLY INTERFACE 23.0'

0
2318156

2318156

Phoenix Contact

CABLE ASSEMBLY INTERFACE 6.56'

0
2304717

2304717

Phoenix Contact

CABLE ASSEMBLY INTERFACE 16.4'

0
2299262

2299262

Phoenix Contact

CABLE ASSEMBLY INTERFACE 19.69'

0
2322702

2322702

Phoenix Contact

CABLE ASSEMBLY INTERFACE 9.84'

0
2304694

2304694

Phoenix Contact

CABLE ASSEMBLY INTERFACE 11.5'

0
2304623

2304623

Phoenix Contact

CABLE ASSEMBLY INTERFACE 4.9'

0
2900127

2900127

Phoenix Contact

CABLE ASSEMBLY INTERFACE 9.84'

0
2321431

2321431

Phoenix Contact

CABLE ASSEMBLY INTERFACE 39.4'

0
2318978

2318978

Phoenix Contact

CABLE ASSEMBLY INTERFACE 19.69'

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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