Sensors in Industrial automation

Sensors in Industrial automation

Sensors in Industrial automation

Sensors in Industrial automation

The sensors are the input devices that can provide an output based on input.

Sensors are playing an important role in industrial automation to make the products intelligent and highly automatic. The sensors allow the analysis, detection, measure, and process of various changes like length, height, appearance, and displacement in the industry.

The industrial sensors include the electronics required to position, detect or identify an object. It includes the technologies are, Magnetoresistive, inductive, pressure, ultrasonic, capacitive, and optical.

The speed sensors are important in industries for moving parts such as gears, shafts, pulleys, etc. The techniques can be used for the speed of sensing. One of the methods is the DC tachometer system. which is connected to a rotating machine. This principle includes dc generator rotates faster, the output voltage increases then it translated into speed.

Industrial automation presents so many opportunities for wireless sensor networks. The areas of the sensors are expected to flexible, and expensive of expendability rates. The sensors technology of the industrial automation and process control market is that it can provide sensing systems.  Batteryless sensor nodes run with energy from vibrating machine parts, electromagnetic waves, temperature, and the waves are infrared and radio waves.  By these sensors, reducing the operating costs, high return on investment drive technology development, enhanced performance in industries such as oil and gas.

Why we use sensors in industrial automation

The main role of a sensor in an automation system is to measure and detect physical effects on the control system. These integrate a variety of sensory information and human knowledge.

The basic sensing elements are small fragile devices. These are for housings to protect harsh environments. These operate in high temperatures, high humidity, moisture, atmospheres, saltwater, shock, vibration, and physical abuse, etc.

Classification of sensors

1.Active Sensors: these sensors require an external power signal.

  1. Passive Sensors: these sensors do not require any external power signal and these sensors generate output response.

Areas for industrial sensors are Electronic assembly, automatic lens grinder depth indicator, overload protected tactile sensor, operation control, hydraulic presses, endurance testing, nut runner, torque control, material testing, hydraulic presses, instrument testing, propulsion systems, position control smart switch, yarn auto-tension for textile industry, waste management, wireless sensors for SCADA control in OIL and Gas fields, etc.

Applications of sensing subsystems in automation

Industrial automation production and operations are can’t be complete without these applications.

In automation the sensors are essential. The applications of sensors in industrial automation are,

Sensing and detection applications are

  • pressure sensing applications
  • optical sensing
  • sensor AFE for many types of sensor
  • system health monitoring and temperature sensing
  • PH and chemical sensing
  • Optical sensing
  • Vibration or motion sensing

System health monitoring

In the health industry, these sensors are very much used to sense and detect different systems’ health parameters. They are

  • Analog temperature sensing
  • Integrated system health monitors ICS
  • Remote diode temperature
  • Temperature switches
  • Thermocouple solutions
  • Resistance temperature detectors

Factory automation

These sensors are used for factory automation operations and processes. And it includes control and automation networks. For example, precision Ethernet PHY with IEEE 1588 PTP.

Motor control

Motor control sensors are AC motor sensors, servo motor control.

Test and measurements

The test and measurement sensors are spectrum analyzers, oscilloscopes. And these sensors are used for automated testing in the industry.

Data acquisition circuits for industrial applications

This type of sensor is highly used in industrial for data processing. These sensors are captured the analog data and converted it to digital data. These types of sensors are, Data acquisition system, I? O sensor module, LIDAR system.

Machine vision and display

In industry, these sensors are used to store, capture and display images. The sensors include security or machine vision, multifunction printers.

List of Different Types of sensors

The different types of sensors which are used in different types of application. The sensors are used for measuring the temperature, capacitance, resistance, conduction, heat transfer, etc.

  • Temperature sensors

The temperature sensors are the electronic devices that provide signals to the inputs of display devices. The specifications include detector or sensor type, min, max measurable temperatures, and length and diameter dimensions.

  • Color sensor
  • Temperature sensor
  • Smoke, gas, and alcohol sensor
  • Proximity sensor
  • Touch sensor
  • Ultrasonic sensor
  • Accelerometer
  • Light sensor
  • IR sensor
  • Pressure sensor
  • Magnetic sensor
  • Humidity sensor
  • Position sensor
  • Tilt sensor
  • Touch sensor
  • Sound sensor
  • Flow and level sensor
  • PIR sensor
  • Strain and weight sensor

The technologies of the sensor include,

• Fiber
• Photoelectric
• Capacitive
• Magnetic
• Inductive
• Ultrasonic


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