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Controllers - Cable Assemblies

Image Part Number Description / PDF Quantity Rfq
2299026

2299026

Phoenix Contact

CABLE ASSEMBLY INTERFACE 13.1'

0
2299107

2299107

Phoenix Contact

CABLE ASSEMBLY INTERFACE 3.28'

0
2322728

2322728

Phoenix Contact

CABLE ASSEMBLY INTERFACE 16.4'

0
2304665

2304665

Phoenix Contact

CABLE ASSEMBLY INTERFACE 9.84'

0
2305897

2305897

Phoenix Contact

CABLE ASSEMBLY INTERFACE 19.69'

0
2305790

2305790

Phoenix Contact

CABLE ASSEMBLY INTERFACE 26.25'

0
2321457

2321457

Phoenix Contact

CABLE ASSEMBLY INTERFACE 45.93'

0
2300575

2300575

Phoenix Contact

CABLE ASSEMBLY INTERFACE 3.28'

0
2304157

2304157

Phoenix Contact

CABLE ASSEMBLY INTERFACE 6.56'

0
2299097

2299097

Phoenix Contact

CABLE ASSEMBLY INTERFACE 1.64'

0
2322485

2322485

Phoenix Contact

CABLE ASSEMBLY INTERFACE 9.84'

0
2314370

2314370

Phoenix Contact

CABLE ASSEMBLY INTERFACE 32.8'

0
2296922

2296922

Phoenix Contact

CABLE ASSEMBLY INTERFACE 3.28'

0
2314545

2314545

Phoenix Contact

CABLE ASSEMBLY INTERFACE 82.0'

0
2318208

2318208

Phoenix Contact

CABLE ASSEMBLY INTERFACE 26.25'

0
2296773

2296773

Phoenix Contact

CABLE ASSEMBLY INTERFACE 32.8'

0
2305907

2305907

Phoenix Contact

CABLE ASSEMBLY INTERFACE 26.25'

0
2314778

2314778

Phoenix Contact

CABLE ASSEMBLY INTERFACE 65.62'

0
2321208

2321208

Phoenix Contact

CABLE ASSEMBLY INTERFACE 9.84'

0
2304953

2304953

Phoenix Contact

CABLE ASSEMBLY INTERFACE 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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