Industrial cable assemblies must withstand conditions that destroy consumer-grade wiring within months: continuous vibration, splash and immersion exposure, chemical contact, extreme temperatures, and mechanical abuse from cable chain (drag chain) applications. Nexharn Connectivity manufactures custom industrial cable assemblies for machine builders, system integrators, and industrial OEMs across automation, energy, and process industries.
Our industrial assemblies are built from cable stock rated for the specific application — PUR jacketed for cable chain use, LSZH for enclosed control cabinets, oil-resistant TPE for machine tools, and armoured cable for mechanical protection — and terminated with industrial-grade connectors from qualified supplier platforms including Souriau, Harting, Amphenol Industrial, Phoenix Contact, and custom proprietary housings.
Industrial Cable Assembly Types
| Assembly Type | Key Specification | Application |
|---|---|---|
| Cable Chain (Drag Chain) Assemblies | Class 6 fine-stranded, PUR jacket, min. bend radius rated for chain | CNC machine tool axes, robot arms, linear actuators |
| Sensor/Actuator Cables (M8/M12) | M8 or M12 A/B/D/X coding, IP67/IP68 | Field sensors, photoelectric eyes, solenoid valves |
| Servo Drive Power Cables | 4-conductor + PE, 0.6/1 kV, shielded, PUR jacket | Servo motor power and encoder connections |
| Fieldbus Cables | PROFIBUS, EtherCAT, PROFINET-rated, shielded | Industrial Ethernet, field-level communication |
| High-Current Power Assemblies | AWG 4–2/0, industrial connectors, 600 V | Motor control centres, switchgear, VFD feeds |
| Armoured Cable Assemblies | SWA or STA armour, IP44–IP68 | Underground runs, mechanical protection zones |
Material Specifications
| Parameter | Standard Industrial Options |
|---|---|
| Conductor | Class 5 (flexible) or Class 6 (fine-stranded) per IEC 60228 |
| Conductor material | Bare copper or tin-plated copper |
| Insulation | XLPE (IEC 60502), PVC (IEC 60227), Silicone (IEC 60245) |
| Jacket materials | PUR (drag chain), LSZH (enclosed spaces), TPE (oil resistance), PVC (general), SWA (mechanical protection) |
| Temperature range | –40 °C to +90 °C (PUR); –25 °C to +105 °C (XLPE) |
| Voltage rating | 300/500 V, 0.6/1 kV, higher on request |
| IP rating | IP20 (open ends) to IP68 (with sealed connectors) |
| Connector brands | Harting Han, Souriau, Amphenol Industrial, Phoenix Contact, Weidmuller |
Applications
- CNC machine tools: Servo drive cables, spindle motor wiring, coolant-resistant I/O harnesses
- Industrial robots: Teach pendant cables, robot base power cables, drag-chain sensor wiring
- Packaging machinery: High-speed conveyor signal cables, motor power assemblies, vision system wiring
- Process industry: Chemical plant instrumentation cables, valve actuator wiring, Ex (explosion-proof) rated assemblies
- Renewable energy: Solar string cables, wind turbine nacelle wiring, inverter power assemblies
- Building automation: BACnet/LON bus assemblies, HVAC control wiring, fire alarm network cables
Quality Certifications
- ISO 9001:2015 – Factory quality management system
- CE (LVD, EMC) – Applicable to completed assemblies for EU export
- IEC 62321 (RoHS) – Substance compliance testing and declaration
- UL/cUL – Available for assemblies using UL-listed wire and connectors
- ATEX / IECEx – Documentation support for Ex-rated connector platforms
Frequently Asked Questions
What drag chain (cable chain) cycle life can Nexharn guarantee?
We specify drag chain assemblies using Class 6 fine-stranded conductors and PUR jacket cable rated by the jacket manufacturer for the stated minimum bend radius and travel speed. For a standard 5 m stroke at 2 m/s with a minimum bend radius of 10× cable OD, we quote 5 million duty cycles minimum. Actual cable selection is verified against the chain manufacturer’s cable specification chart.
Can Nexharn supply PROFIBUS and EtherCAT-certified cable assemblies?
Yes. We build PROFIBUS DP assemblies using cable stock certified to IEC 61158-2 (120 Ω characteristic impedance) with purple TPE jacket and terminator resistor network options. EtherCAT assemblies use Cat5e or Cat6A industrial Ethernet cable with IP20 or IP67 RJ45 or M12 D-code connectors. Test reports for characteristic impedance and attenuation are available on request.
What is the standard lead time for industrial cable assemblies?
Lead time is 15–30 days from drawing approval. Assemblies using standard M8/M12 connectors from Nexharn stock typically ship in 15–20 days. Assemblies requiring special connectors from global distribution (Harting, Souriau, Amphenol Industrial) are subject to component lead times of 5–15 additional days. Contact us with a component BOM for a lead time commitment.