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Controllers - Cable Assemblies

Image Part Number Description / PDF Quantity Rfq
2900143

2900143

Phoenix Contact

CABLE ASSEMBLY INTERFACE 9.84'

0
2305884

2305884

Phoenix Contact

CABLE ASSEMBLY INTERFACE 13.1'

0
2321114

2321114

Phoenix Contact

CABLE ASSEMBLY INTERFACE 6.56'

0
2904076

2904076

Phoenix Contact

CABLE ASSEMBLY INTERFACE 6.56'

359
2900149

2900149

Phoenix Contact

CABLE ASSEMBLY INTERFACE 6.56'

0
2301134

2301134

Phoenix Contact

CABLE ASSEMBLY INTERFACE 3.28'

0
2314163

2314163

Phoenix Contact

CABLE ASSEMBLY INTERFACE 6.56'

0
2293909

2293909

Phoenix Contact

CABLE ASSEMBLY INTERFACE 19.69'

0
2322618

2322618

Phoenix Contact

CABLE ASSEMBLY INTERFACE 16.4'

0
2318965

2318965

Phoenix Contact

CABLE ASSEMBLY INTERFACE 16.4'

0
2321347

2321347

Phoenix Contact

CABLE ASSEMBLY INTERFACE 13.1'

0
2321651

2321651

Phoenix Contact

CABLE ASSEMBLY INTERFACE 6.56'

0
2293831

2293831

Phoenix Contact

CABLE ASSEMBLY INTERFACE 4.9'

0
2318680

2318680

Phoenix Contact

CABLE ASSEMBLY INTERFACE 19.69'

0
2904438

2904438

Phoenix Contact

CABLE ASSEMBLY INTERFACE 49.21'

0
2904435

2904435

Phoenix Contact

CABLE ASSEMBLY INTERFACE 39.4'

0
2904429

2904429

Phoenix Contact

CABLE ASSEMBLY INTERFACE 19.69'

0
2904430

2904430

Phoenix Contact

CABLE ASSEMBLY INTERFACE 23.0'

0
2318677

2318677

Phoenix Contact

CABLE ASSEMBLY INTERFACE 13.1'

0
2904443

2904443

Phoenix Contact

CABLE ASSEMBLY INTERFACE 65.62'

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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