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Controllers - Cable Assemblies

Image Part Number Description / PDF Quantity Rfq
2904437

2904437

Phoenix Contact

CABLE ASSEMBLY INTERFACE 45.93'

0
2318622

2318622

Phoenix Contact

CABLE ASSEMBLY INTERFACE 1.64'

0
2904444

2904444

Phoenix Contact

CABLE ASSEMBLY INTERFACE 82.0'

0
2318648

2318648

Phoenix Contact

CABLE ASSEMBLY INTERFACE 4.9'

0
2904434

2904434

Phoenix Contact

CABLE ASSEMBLY INTERFACE 36.1'

0
2904431

2904431

Phoenix Contact

CABLE ASSEMBLY INTERFACE 26.25'

0
2904426

2904426

Phoenix Contact

CABLE ASSEMBLY INTERFACE 9.84'

0
2904524

2904524

Phoenix Contact

VIP-CAB-FLK14/16/10 0M/S7

0
2904425

2904425

Phoenix Contact

CABLE ASSEMBLY INTERFACE 6.56'

0
2904439

2904439

Phoenix Contact

CABLE ASSEMBLY INTERFACE 52.5'

0
2318813

2318813

Phoenix Contact

CABLE ASSEMBLY INTERFACE 6.56'

0
2904445

2904445

Phoenix Contact

CABLE ASSEMBLY INTERFACE 98.4'

0
2904432

2904432

Phoenix Contact

CABLE ASSEMBLY INTERFACE 29.5'

0
2904441

2904441

Phoenix Contact

CABLE ASSEMBLY INTERFACE 59.1'

0
2904440

2904440

Phoenix Contact

CABLE ASSEMBLY INTERFACE 55.78'

0
2904427

2904427

Phoenix Contact

CABLE ASSEMBLY INTERFACE 13.1'

0
2904424

2904424

Phoenix Contact

CABLE ASSEMBLY INTERFACE 3.28'

0
2904433

2904433

Phoenix Contact

CABLE ASSEMBLY INTERFACE 32.8'

0
2904442

2904442

Phoenix Contact

CABLE ASSEMBLY INTERFACE 62.34'

0
2904428

2904428

Phoenix Contact

CABLE ASSEMBLY INTERFACE 16.4'

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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