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Controllers - Cable Assemblies

Image Part Number Description / PDF Quantity Rfq
2981826

2981826

Phoenix Contact

CABLE ASSEMBLY INTERFACE 8.2'

5
2305198

2305198

Phoenix Contact

CABLE ASSEMBLY INTERFACE 13.1'

0
2299563

2299563

Phoenix Contact

CABLE ASSEMBLY INTERFACE 26.25'

0
2314147

2314147

Phoenix Contact

CABLE ASSEMBLY INTERFACE 3.28'

0
2296812

2296812

Phoenix Contact

CABLE ASSEMBLY INTERFACE 1.64'

0
2296825

2296825

Phoenix Contact

CABLE ASSEMBLY INTERFACE 3.28'

0
2299246

2299246

Phoenix Contact

CABLE ASSEMBLY INTERFACE 9.84'

0
2318088

2318088

Phoenix Contact

CABLE ASSEMBLY INTERFACE 9.84'

0
2293912

2293912

Phoenix Contact

CABLE ASSEMBLY INTERFACE 23.0'

0
2314516

2314516

Phoenix Contact

CABLE ASSEMBLY INTERFACE 82.0'

0
2322582

2322582

Phoenix Contact

CABLE ASSEMBLY INTERFACE 8.2'

0
2304636

2304636

Phoenix Contact

CABLE ASSEMBLY INTERFACE 4.9'

0
2321774

2321774

Phoenix Contact

CABLE ASSEMBLY INTERFACE 26.25'

0
2900151

2900151

Phoenix Contact

CABLE ASSEMBLY INTERFACE 13.1'

1
2321402

2321402

Phoenix Contact

CABLE ASSEMBLY INTERFACE 45.93'

0
2321127

2321127

Phoenix Contact

CABLE ASSEMBLY INTERFACE 9.84'

0
2299152

2299152

Phoenix Contact

CABLE ASSEMBLY INTERFACE 19.69'

0
2321143

2321143

Phoenix Contact

CABLE ASSEMBLY INTERFACE 19.69'

0
2318321

2318321

Phoenix Contact

CABLE ASSEMBLY INTERFACE 4.9'

0
2299136

2299136

Phoenix Contact

CABLE ASSEMBLY INTERFACE 9.84'

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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