Sensor cables essentially act as the ‘nervous system’ between the sensors and actuators. They transmit data, power, and signals in automation. However, choosing the wrong sensor cable can lead to signal loss, downtime, electrical noise, and incompatibility. In this blog, we will use our expertise to give you a step-by-step guide on choosing the right sensor cables for your needs.
Understanding the Basics of Sensor Cables
A sensor cable is used to transmit sensor signals with integrity and durability. They are specially engineered to accurately transmit weak, low-voltage, or high-frequency signals, including temperature, pressure, or motion data.
Sensor cables connect sensors, transducers, and measuring devices to control systems like PLCs, monitoring equipment, or data acquisition systems. They’re commonly used in:
- Industrial automation
- Process control
- Robotics
- Automotive
- Medical equipment
Step-by-Step Buyers Checklist
We’ve pulled together our expertise to create a comprehensive checklist for choosing the right sensor cable for your needs.
Define Your Application Requirements
Before choosing your sensor cable, you should start by clarifying the sensor’s role and installation environment. Consider:
- What type of sensor is being used – e.g. proximity, pressure, temperature?
- Is the cable mostly static or subject to repeated motion?
- Is it part of an industrial system, automotive application, or outdoor monitoring setup?
The application influences choices such as jacket material, shielding, connector type, and length.
Choose Cable Type and Construction Materials
The construction of the cable defines how well a cable will cope in its environment. What is necessary for static indoor use is completely different to what is needed for industrial robotics. Here is a table where you can compare common materials based on your needs:
| Material | Best For | Pros | Cons |
| PVC (Polyvinyl Chloride) | Static indoor use | Low cost, general purpose | Not ideal for high flex or harsh chemicals |
| PUR (Polyurethane) | Highly flexible, industrial robotics | Excellent abrasion & oil resistance | Higher cost |
| TPE (Thermoplastic Elastomer) | Weather and temperature range | Good flexibility & cold temp performance | Mid-range cost |
| Silicone / FEP / ETFE | High heat or chemical environments | Extreme temp tolerance | Higher specialised cost |
| PTFE | High temperature, aerospace, or harsh environments | Excellent heat resistance, chemical resistance, and flame retardant | Higher cost, less flexible |
| FEP | High temperature, chemical environments | Good electrical performance and flame-retardant | More expensive |
| XLPE/XLPO | Outdoor, UV, and weather exposure | Excellent UV, water, oil, and chemical resistance | Specialist use and higher cost |
Different types of sensor cables are engineered for static vs dynamic builds. Most are suitable for static installations, but for motion-intensive applications like robotics or drag chain sets, chain-flex or dynamic cables with PVC or PUR jackets are generally recommended to handle repeated flexing.
Some sensor cables are also designed to be flame-retardant for safety compliance. They protect high-temperature environments or environments where safety is critical. These include:
- PTFE
- FEP
- XLPE
- XLPO
These flame-retardant cables are commonly used in aerospace and high-temperature industrial applications.
Shielding
Shielding is essential to get right when choosing your sensor cables, as it protects sensor signals from electromagnetic interference (EMI) caused by motors, drives, and electrical switching.
Common shield types include:
- foil screens – lightweight and cost-effective, great for standard applications.
- braided screens – made from woven copper or tinned wire for superior strength.
- armoured cables – used in situations where the cable is exposed outdoors or in harsh environments.
Environmental and Mechanical Conditions
Being aware of the environmental conditions that your sensor cable will be used in will help you select the cables with the right protective features. Environmental factors you need to consider include:
- Temperature exposure (high/low) – for high-temperature applications, high-performance cables such as PTFE or FEP cables are ideal as they can withstand extreme heat.
- Oil, chemicals, and abrasion exposure – PUR jackets are excellent at resisting oils, while XLOE/XLPO are suited for exposure to oil, chemicals, and abrasive environments.
- UV exposure/outdoor-rated jackets – XLPE/XLPO jackets are recommended for prolonged outdoor use or direct sunlight due to great weather and UV resistance.
- Drag chains or continuous motion paths – cables used in these applications should have flexible, high-cycle designs like PUR or FEP.
Cable Length and Installation Considerations
Most industrial sensor cables are available in standard lengths, including 0.5m up to 20m+. longer lengths generally increase signal attenuation, and may need shielding, twisted pairs, or repeaters. Options generally include:
- Pre-cut lengths – 0.5m, 1m, 3m, 5m, 10m, 15m, 20m — common for modular installations.
- Custom lengths – essential when standard lengths lead to excess waste or stretching.
- Open-end cables – a cable with no connector on one end, for custom termination in control panels or junction boxes.
When choosing the correct sensor cable length, you should always plan slightly more length than needed to allow for routing around obstacles and strain relief.
Compliance
Sensor cables must meet regulatory standards depending on the type of application. Not all industries and applications have the same compliance requirements, so it’s important to research this deeply.
Looking for Quality Sensor Cables?
At K. Lacey, we have a team of experts who can help you choose the best sensor cable for your needs. Whether you handle robotics, factory automation, process control, test & measurement, or harsh-environment installations, we’ll guide you to a solution that delivers reliability, durability, and signal integrity.
With decades of industry expertise, a wide product range, and custom cable assembly options, we make specifying the right sensor cable simple and stress-free.