Sensor technology is constantly advancing. It started with simple mechanical switches and basic devices designed to detect the presence or absence of an object, relying heavily on mechanical and electromechanical principles. Today’s sophisticated smart sensors enhance technology quality. materials performance, detection speed, and accuracy. They use a range of physical principles, including inductive, capacitive, optical, ultrasonic, or magnetic solutions, to detect objects with greater precision.

Meeting modern demands

Modern customers now expect precise detection of length, position, angle, inclination, level, distance, pressure, etc., for all materials, including plastic, wood, iron, glass, and liquids. I would say that there are few applications that cannot be solved with today’s technology.

Yes, some projects require unique external environments such as pressure, temperature, or atmosphere. However, even in these areas, progress is pushing the boundaries of what is possible. The key evolution is that customers now expect suitable solutions, and sensor requirements are changing in new areas. These new anomalies must be detected, but they are not directly related to the original sensor detection.

Expanding capabilities with smart sensors

Customers increasingly need sensors that provide additional parameters to prevent production or machine downtime caused by poorly planned maintenance or equipment faults. These smart sensors can easily gather a wide range of data, including information on vibrations, temperature, humidity, operating hours, boot cycle counter, device discovery, voltage/current monitoring, and inclination. This expanded capability ensures more reliable and efficient operations.

Condition monitoring systems, for example, are ideal solutions for preventing unplanned downtimes and related costs. They offer deep insights into the actual condition of your machines and systems, allowing you to detect deviations and issues early and allowing intervention before a failure occurs. These systems collect physical data such as vibration and temperature and transmit it to higher-level systems through communication protocols.

Integrating smart sensors with existing systems

If you prefer not to alter your existing setup, no problem. You can keep using your reliable simple sensors and add dedicated condition monitoring sensors. This way, your wiring structure remains unchanged, and you gain the advantage of monitoring machine parameters like vibration, inclination, internal temperature, and humidity with easily integrated sensors.

This way, you can optimize maintenance, leading to process improvements, cost reductions, and enhanced employee safety. Additionally, you can anticipate failures and minimize costs associated with production delays.