Initially, they were used to reduce manual labor and trigger mechanical responses. As sensor technology advanced, companies developed devices to analyze manufacturing processes, identify areas for improvement, and collect data from individual machines.

Given the rise of machine monitoring solutions and Industrial IoT, manual data analysis and simple mechanical responses to sensor inputs have become inefficient and unnecessary. With increased capabilities to collect, analyze, and process data in terms of speed and accuracy, sensor technology has evolved from being a stopping point for automated processes to feeding IoT systems.

Today, manufacturing sensors continue to be an essential piece of the IoT and data collection puzzle. Manufacturers recognize that while industrial sensors will still be needed in the foreseeable future, advances in IoT are helping define their role in factory environments and data collection.

What Are Manufacturing Sensors?

Manufacturing sensors are used to collect data by measuring the physical conditions within a machine. They consist of a device that receives or measures inputs and produces data as outputs. This data can be used to trigger a machine response or collect information for analysis and storage.

A wide range of industrial sensors is available for various types of measurements. Today, thanks to smart sensors, data can be processed and analyzed before being sent to the cloud. This information can be used for various purposes, such as filling a production board or simply collecting data for historical analysis.

Real-time data collection, utilizing various communication methods like 5G, Wi-Fi, cellular connectivity, and Ethernet, allows platforms to generate insights that help improve manufacturing processes, reduce costs, and enable predictive maintenance.

Machine data platforms make it possible to collect data alongside sensors to ensure that raw data from all equipment is captured and standardized in a common model for actionable insights.

Types of Sensors Used in Manufacturing

What are some common types of sensors used in industrial environments?

Three-Axis Accelerometers

Many rotating parts exist in manufacturing equipment. A three-axis accelerometer monitors and measures vibrations in rotating parts and equipment. These smart sensors can also measure other variables like displacement, acceleration, and speed. Combined with IoT’s advanced analytics, this data can provide valuable information for managers and technicians to know whether a machine is functioning healthily or if a deviation is a one-time occurrence or a problematic pattern.

Temperature Sensors

Moving equipment generates a lot of heat, and many industries use additional process heat for factory floors. Heat is an excellent indicator of a machine’s overall health. Temperature sensors can help identify wear, damaged parts, and overheating that lead to failure and quality control issues.

Vibration Sensors

Vibrations don’t only occur in rotating parts. Vibration sensors can be used with conveyors, panels, and other machine parts to alert operators and technicians when something is wrong.

MEMS (Micro-Electromechanical Systems) Sensors

MEMS sensors are motion sensors that monitor movement and performance. At its simplest, they detect motion and trigger a machine response to realign a component of the equipment.

Torque Sensors

High-speed motors can generate strong torque forces in a machine. These forces are even more significant under load. When torque sensors monitor a motor or shaft, they can help manufacturers ensure quality, reduce machine wear, and fix issues before they arise. These smart sensors are often combined with others to create a highly detailed view of equipment health.

Pressure Sensors

Pressure sensors monitor all machine components used by liquids or gases, including hydraulics, water, chemicals, air, and nitrogen. They can be set to alert the factory monitoring system when high or low limits are reached.

Data Management for Smart Sensors

Smart sensors unlock the potential of big data as they provide the data needed for IoT’s advanced analytics to operate. However, this data needs context and standardization to create value for users and systems.

Contextual Data

Contextual data means adding relevant real-world information to sensor data sent to the IoT platform. Without context, raw data may not be helpful to users. For example, it is essential for manufacturers to track and analyze downtime events. However, without operator input on the “why” behind a downtime event, the data is less helpful.

Relevant Data

Simply capturing data is not enough—the data collected must be relevant. This means smart sensors need to select high-value information and discard redundant or unnecessary data.

Standardized Data

Sensors can provide data, but it is the job of the IoT platform to ensure that the data is standardized across all equipment and devices. Without data standardization, there would be a confusing mix of different data types that wouldn’t allow stakeholders or other systems to take actionable steps.

Actionable Data

Equipment data is vital for enhancing operational efficiency and productivity as it presents an accurate picture of manufacturing performance that can be shared as actionable insights across the workshop. Actionable data with real-time notifications allows operators to take proactive steps to reduce downtime and failure between machines. It also gives managers complete operational visibility.

How Do Industrial Sensors Improve Manufacturing?

Industrial sensors improve manufacturing by providing actionable insights to the factory floor and beyond, integrated with advanced IoT platforms. Smart sensor technology contributes to this ecosystem by offering superior visibility into machine conditions, processes, production, and more.

In this ecosystem, industrial sensors (along with direct connections to machine data where sensors aren’t required) help capture data that can improve manufacturing processes, enable predictive maintenance schedules, and reduce operating costs.

Applications of Digital Sensors in Manufacturing

There are many applications for digital sensors in manufacturing, including:

Data-Driven Insights

When combined with advanced IoT, industrial sensors collect data that can be turned into valuable, actionable insights in real time for users. This is revolutionizing the factory floor and workshop by allowing personnel to monitor, adjust, and improve operations.

Safety

As part of a system deeply connected to AI-powered analytics, digital sensors can provide safety advantages to a company. This might include precise work stoppage when a hazard is detected or real-time notifications to emergency personnel before a crisis. For example, if a machine tool experiences more load than usual, it can automatically stop to prevent severe tool failure.

Improved Maintenance Schedules

IoT with digital sensors allows maintenance personnel to detect equipment failures and initiate a procedure before the equipment breaks down. It can also be used to schedule maintenance at the most optimal time.

Accurate Historical Data

Many manufacturing companies deal with extensive regulatory compliance. With data returned from smart sensor technology and organized in the cloud, accurate production records provide better transparency and a product audit trail. This allows managers to establish precise manufacturing criteria and predict performance.

Procedure and Quality Notification

Many manufacturing companies require strict adherence to procedures. This is especially true for industries like CNC machining for medical and aerospace. Since these procedures can be added as contextual data, sensors can detect if a procedure is off track and alert managers. The same applies to quality notifications, which are especially crucial in highly regulated environments.

Improve Information Flow and Market Response

The power of real-time data lies in the ability to take immediate, proactive action. This means that information is at the fingertips of everyone in the business. Responding to market trends, whether good or bad, helps a company adapt quickly to changing conditions and stay competitive.

The Future of Sensors in Manufacturing

Sensors enable a truly connected operation by delivering real-time diagnostic data that provides in-depth insights from advanced analytics engines in the cloud. This allows manufacturers to access data from all equipment, even legacy assets, indicating that sensors will continue to play a role in the foreseeable future.

However, sensors alone are not capable of providing advanced use cases or effective machine monitoring. They require technical resources to collect, standardize, and visualize data. Yet, sensors and an IoT Platform help ensure accurate and reliable data capture throughout the workshop.