A Complete Guide to Sensor Cable and Connectors

Sensor connectors are primarily used in conjunction with sensor cables, actuator cables, and switch cables for a variety of different industrial applications. They are quite versatile connectors, typically available in a wide range of different materials, sizes and lengths to suit a selection of industrial components and applications.

They are used to connect sensing devices and components such as proximity sensors, photoelectric sensors, ultrasonic sensors, and current transducers, providing a durable and secure connection. Sensor connectors typically also feature coded ends offering various pin layouts for greater choice and flexibility.

Alongside sensor and actuator cables, sensor connectors feature technology which enables them to integrate into industrial automation processes and systems seamlessly. In short, these connectors are used to join the corresponding cables and components with the switches, sensors, and equipment which make up the industrial automation process. All of these separate components are then joined together to work as one automated unit, providing an efficient system able to work at maximum efficiency, increase productivity, and minimise downtime.

Sensor and actuator cables and connectors can be used with multiple different types of switches and sensors across a wide variety of industries and sectors. However, they are commonly used in industrial process control and automation environments within the manufacturing and food and beverage industries.

These connectors can also be used with the majority of switches, sensors and cables which feature an IO-Link interface or those which have ATEX approval.

IO-Link

IO-Link is an industrial communication and networking standard. It is primarily used in industrial automation to connect components like sensors to various types of industrial Ethernet or Fieldbus. IO-Link provides a secure, wired connection, ideal for travelling shorter distances between different fixed points.

ATEX

ATEX is a type of certification used in Europe for testing and approving equipment. The approval ratings are designed for components that are likely to be used in potentially hazardous environments, and it is a standard required to confirm that equipment is safe for use in these areas.

There are multiple different types of sensor connectors, each suitable for varying uses and applications. From different sized connectors to connector genders, voltages, and more, it is essential to select the most appropriate type of sensor connector for your setup.

Some of the main types of sensor connectors you may encounter are explored in the sections below.

O2 Sensor Connectors

O2 (oxygen) sensors are primarily used in vehicles and the automotive industry to monitor the levels of unburned oxygen exiting vehicles via the exhaust. These sensors can help mechanics to gauge the vehicle’s fuel and oxygen consumption accurately and determine if the engine is burning lean (higher levels of oxygen) or rich (lower levels of oxygen). Connectors are used alongside these O2 sensors and cables to integrate the sensor into the setup fully. It is also important to note that grease should not be used with O2 sensor connectors as this could cause an airflow blockage.

Pressure Sensor Connectors

Pressure sensor connectors and adapters can be used alongside pressure sensors for a comprehensive sensing solution. They are found in a variety of pressure sensing applications and are suitable for use with substances such as fuel, liquids, and oil. In specific scenarios, pressure sensor connectors can also be found alongside throttle position sensors.

Speed Sensor Connectors

Speed sensors are similar to tachometers and are designed to monitor and record the speed of a wheel’s rotation. They are most commonly used in vehicles but can be used in any application requiring reliable movement direction and speed detection of a wheel or designated component. Speed sensor connectors are available in various forms, providing the flexibility to incorporate the connector into a new or existing setup easily.

Temperature Sensor Connectors

Temperature sensors measure and document the temperature of their surroundings, providing an accurate record of temperature data and changes over time. Both contact and non-contact temperature sensors are available, each best suited to different applications. Temperature sensor connectors are used with these devices to provide a complete, connected sensing solution.