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Controllers - Cable Assemblies

Image Part Number Description / PDF Quantity Rfq
2305868

2305868

Phoenix Contact

CABLE ASSEMBLY INTERFACE 32.8'

0
2903470

2903470

Phoenix Contact

CABLE ASSEMBLY INTERFACE 6.56'

0
2304160

2304160

Phoenix Contact

CABLE ASSEMBLY INTERFACE 3.28'

0
2900156

2900156

Phoenix Contact

CABLE ASSEMBLY INTERFACE 6.56'

0
2318541

2318541

Phoenix Contact

CABLE ASSEMBLY INTERFACE 1.64'

0
2296731

2296731

Phoenix Contact

CABLE ASSEMBLY INTERFACE 13.1'

0
2304704

2304704

Phoenix Contact

CABLE ASSEMBLY INTERFACE 16.4'

0
2305266

2305266

Phoenix Contact

CABLE ASSEMBLY INTERFACE 4.9'

0
2981635

2981635

Phoenix Contact

CABLE ASSEMBLY INTERFACE 8.2'

0
2900147

2900147

Phoenix Contact

CABLE ASSEMBLY INTERFACE 3.28'

0
2302502

2302502

Phoenix Contact

CABLE ASSEMBLY INTERFACE 9.84'

0
2986999

2986999

Phoenix Contact

CABLE ASSEMBLY INTERFACE 8.2'

0
2314309

2314309

Phoenix Contact

CABLE ASSEMBLY INTERFACE 9.84'

0
2296948

2296948

Phoenix Contact

CABLE ASSEMBLY INTERFACE 6.56'

0
2296838

2296838

Phoenix Contact

CABLE ASSEMBLY INTERFACE 6.56'

0
2305952

2305952

Phoenix Contact

CABLE ASSEMBLY INTERFACE 1.64'

0
2304908

2304908

Phoenix Contact

CABLE ASSEMBLY INTERFACE 6.56'

0
2293828

2293828

Phoenix Contact

CABLE ASSEMBLY INTERFACE 3.28'

0
2900145

2900145

Phoenix Contact

CABLE ASSEMBLY INTERFACE 19.69'

0
2305350

2305350

Phoenix Contact

CABLE ASSEMBLY INTERFACE 3.28'

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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