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Controllers - Cable Assemblies

Cable assemblies are essential components of a wide range of controllers. For industrial purposes, these are used in robotic assembly lines and other automated systems that rely on precise motion control. In a decentralized architecture, a cable assembly can be used to link electrical control systems over long distances, and are available in various configurations – ranging from two-wire assemblies to those with many more wires. Along with cable assemblies, a controller is also often integrated into the system to ensure that the desired motion, speeds and force are achieved.

A cable assembly is made up of several components, beginning with an insulation material that can withstand the expected temperatures and environments in which the system will be operated. This insulation material can be applied in various ways, and the most common forms are either PVC or elastomeric sheathing that are extruded over the major components within the assembly.

The next step in the process involves the wire interconnects and terminals. Generally, a cable assembly includes individual wires with appropriate insulation and shielding. Some cables even have multiple conductor groups twisted together to better reduce electromagnetic interference (EMI) noise. The wires are then terminated with the connectors required for their application. These can be both insulated and un-insulated terminals that help to keep moisture and dirt from entering the cables.

In a typical application, the cable assembly needs to make a connection between two components located in different areas. If the components are stationary, the cable assembly is usually pre-formed into an exact length before it is sent out for installation, and then it is cut to fit, and any ends are properly stripped to expose the conductors. However, if the components are movable, the cable assembly must be adjustable to the required length. In these cases, two ends of the cable assembly are typically fitted with adjustable slides.

Whatever the configuration, the controller is integral in achieving desired motion, speeds and force. By connecting to a network of sensors and actuators, the controller tracks the motion of the components and regulates the cable assembly accordingly. In this way, a single controller can be used to smoothly move multiple components and control each cable assembly in the system.

Though a cable assembly can operate without the presence of a controller, its functionality is greatly enhanced when connected to a high-precision motion control system. This type of integration enables precise, automated control of the motion of the component, and helps ensure efficient operation of the system as a whole. When combined with a controller, the cable assembly can provide precise control of the system and help to reduce cost and improve efficiency.

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