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Controllers - Cable Assemblies

Image Part Number Description / PDF Quantity Rfq
2304791

2304791

Phoenix Contact

CABLE ASSEMBLY INTERFACE 3.28'

0
2289049

2289049

Phoenix Contact

CABLE ASSEMBLY INTERFACE 11.5'

0
2305774

2305774

Phoenix Contact

CABLE ASSEMBLY INTERFACE 13.1'

11
2296919

2296919

Phoenix Contact

CABLE ASSEMBLY INTERFACE 1.64'

0
2321800

2321800

Phoenix Contact

CABLE ASSEMBLY INTERFACE 6.56'

0
2305910

2305910

Phoenix Contact

CABLE ASSEMBLY INTERFACE 32.8'

0
2904646

2904646

Phoenix Contact

CABLE ASSEMBLY INTERFACE 32.8'

0
2322472

2322472

Phoenix Contact

CABLE ASSEMBLY INTERFACE 8.2'

0
2304898

2304898

Phoenix Contact

CABLE ASSEMBLY INTERFACE 3.28'

0
2318130

2318130

Phoenix Contact

CABLE ASSEMBLY INTERFACE 3.28'

0
2314176

2314176

Phoenix Contact

CABLE ASSEMBLY INTERFACE 8.2'

0
2318790

2318790

Phoenix Contact

CABLE ASSEMBLY INTERFACE 3.28'

0
2314480

2314480

Phoenix Contact

CABLE ASSEMBLY INTERFACE 19.69'

0
2322443

2322443

Phoenix Contact

CABLE ASSEMBLY INTERFACE 1.64'

0
2299013

2299013

Phoenix Contact

CABLE ASSEMBLY INTERFACE 9.84'

0
2304814

2304814

Phoenix Contact

CABLE ASSEMBLY INTERFACE 9.84'

0
2302544

2302544

Phoenix Contact

CABLE ASSEMBLY INTERFACE 9.84'

0
2321046

2321046

Phoenix Contact

CABLE ASSEMBLY INTERFACE 9.84'

0
2321680

2321680

Phoenix Contact

CABLE ASSEMBLY INTERFACE 19.69'

0
2321253

2321253

Phoenix Contact

CABLE ASSEMBLY INTERFACE 1.64'

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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