Sensor & Actuator Cables

A sensor actuator cable is a specialised component essential for the infrastructure of modern industrial automation and control systems. These cables facilitate precise signal and data transmission across networks while efficiently delivering power between control units, sensors, and actuators. In automated machinery, actuators convert electrical signals into mechanical motion, while a dedicated sensor cable or sensor wire carries critical position, temperature, pressure, and proximity feedback in the reverse direction to the central controller.

RS Australia stocks sensor actuator cables and matching connectors in shielded, unshielded, fixed-installation and continuous-flex builds, including assemblies from leading brands like Phoenix Contact, HARTING and more. Order and enjoy fast nationwide delivery.

Construction of Sensor Cables

Often, sensor cables are used in demanding and harsh industrial environments, therefore, the cables must be robust, tough and flexible. This robust construction of sensor cables is critical to their performance and longevity:

• Materials: The choice of materials is dictated by the environment the sensor cable will operate in. TPE (Thermoplastic Elastomer) offers excellent flexibility and durability, making it ideal for dynamic environments subject to frequent bending. Outer jackets are available in PVC, PUR, TPE, TPU or halogen-free.
• Protection Ratings: High IP ratings are necessary for sensor cables used in outdoor or wet environments to prevent ingress of moisture and dust that could damage the cable's internal components. Cables can be IP67-rated for protection from water and dust ingress.
• Shielding: This is crucial for preventing electromagnetic interference (EMI) from affecting the data being transmitted through the cables. Effective shielding is essential in environments with high electromagnetic noise, such as near heavy machinery or power lines. Three screening constructions cover most industrial work:
• Foil Screen: Aluminium-polyester tape giving full coverage and good high-frequency performance. Light and inexpensive, but it tears under repeated flexing, so use it on fixed runs.
• Braid Screen: Tinned copper braid at 70 to 90 percent coverage. Lower coverage than foil but more robust and better at low frequencies, so it suits moving cables.
• Foil Plus Braid: Both layers together for broadband screening. Typically specified where a sensor run shares a duct or cable tray with drive cables.

Shielding becomes mandatory where a signal cable runs near a variable speed drive, servo amplifier or switched motor circuit. These switch large currents at high frequency, and the radiated noise can corrupt an analogue 4-20mA signal or drop packets on an industrial Ethernet segment.

Termination is where most shielded installations fail. A screen twisted into a pigtail performs barely better than an unshielded run. The screen needs a 360-degree bond to the connector body or an EMC gland at the enclosure entry, and the earthing convention must be consistent across the panel.

Types of Sensor Cables

RS Australia stocks an extensive range of sensor cable assemblies engineered for diverse environmental conditions, mounting requirements, and dynamic motion profiles across automated sites:

• Sheath Materials & Environmental Protection: Features PVC jackets for general-purpose indoor installations, Alongside oil-, chemical-, and abrasion-resistant PUR and TPE outer sheaths designed for harsh machining environments and continuous washdowns.
• M5, M8, M12 & M23 Connector Profiles: Supplies straight and right-angled sensor actuator connectors across 3-pin, 4-pin, 5-pin, and 8-pin pole configurations to deliver secure, IP-rated mechanical locking for fast field maintenance.
• Conductor Sizing & Cross-Sectional Area: Offers a comprehensive selection of core conductor sizes to meet specific current-carrying capacities and prevent signal voltage drop over extended cable runs.
• High-Flex & Drag-Chain Construction: Incorporates fine-stranded conductors and low-friction jackets built for continuous movement in cable carriers, gantries, and robotic arms, supporting dynamic bend radii of 7.5 to 10 times the outer cable diameter.
• Fixed-Installation Sensor Wire: Provides cost-effective static sensor wire designed for permanent conduit runs and stationary equipment, requiring a minimum bend radius of 4 to 5 times the cable diameter.

Industrial Applications of Actuator Cables

RS Australia supplies high-performance sensor actuator cable assemblies across key Australian sectors to maintain precise motion control, minimise operational downtime, and ensure regulatory compliance:

• Automated Manufacturing & Robotics: Transmits high-speed feedback signals and power to electric linear actuators, robotic end-effectors, and assembly line positioning systems.
• Materials Handling & Logistics: Delivers reliable signal transmission for proximity sensors, photoelectric barriers, and automated guided vehicles across high-density distribution centres.
• Food & Beverage Processing: Uses hygienic, chemical-resistant sensor cable lines to connect position transducers and automated control valves in intensive washdown environments.
• Process Industries & Water Treatment: Connects remote pressure, temperature, and flow switches to central PLCs across chemical processing plants and municipal pumping stations.
• Agriculture & Outdoor Mobile Plant: Utilises ruggedised, UV-stable sensor wire to operate linear actuators in automated sorting equipment, harvesting machinery, and solar tracking arrays.

Ordering Sensor Actuator Cables From RS

RS is a supplier and distributor of sensor actuator cables in Australia, holding enough inventory for procurement teams to match connector type, cable length and rating from a single supplier. RS stocks sensor cables and sensor wires sourced directly from brands like Phoenix Contact, SICK, Harting and many more, so every part ships as genuine stock under full manufacturer warranty. Place orders online or by phone, email and fax, with bulk and project orders accommodated at special volume pricing quoted on request.

Procurement teams can consolidate orders by sourcing proximity sensors, DIN rail terminal blocks and general purpose enclosures at the same time, making RS a one-stop procurement source for a complete sensing installation.

Delivery Information for Australia

RS delivers sensor actuator cables across Australia. Online orders over $60 (excluding GST) are delivered free on a business account, and stock held locally ships on the next working day delivery when ordered before 5pm AEST.

Delivery Charges on Online Orders

• Business Accounts (with a valid ABN or an RS credit account):
  • Delivery is free on orders over $60 (excluding GST)
  • Orders under $60 (excluding GST) incur a $10 delivery charge
• Private and Guest Accounts:
  • Delivery is free on orders over $80 (excluding GST)
  • Orders under $80 (excluding GST) incur a $20 delivery charge

Next Working Day Delivery

• Order locally stocked items before 5pm AEST, Monday to Friday
• Orders placed after 5pm Friday arrive Tuesday

For the complete terms, see the RS Australia delivery page, which lists all delivery options, exclusions and fees.