Industrial IoT Sensors: What Are They and Which Businesses Use Them

Industrial IoT sensors are widely used in different industries to monitor equipment, assets, systems, and overall performance. Real-time data is then analyzed and transmitted to a company’s centralized system. Management can then make informed decisions about maintenance priorities and future asset replacement needs.

What is an Industrial IoT Sensor?

An Industrial Internet of Things (IIoT) sensor monitors machines and systems to provide real-time data to a maintenance staff. Instead of relying on periodic checks by maintenance technicians, IIoT sensors provide around-the-clock “eyes” on critical assets. This means equipment stays up and running more reliably and that minor issues are caught immediately before major breakdowns occur.

What’s the Difference Between IoT and IIoT?

The difference between IoT and IIoT lies in the how rigorous the standards are. The Internet of Things is a broader category, which includes any device that can be connected to the internet like a common smartphone. The Industrial Internet of Things falls under IoT and refers to a more technical subgroup that requires rigorous standards. These standards ensure that data from proprietary systems or complex machinery stays secure.

3 Benefits of IIoT Sensors

IIoT sensors help businesses keep better tabs on their equipment and data, reduce cost, and realize better integration of information. The primary benefits all mean greater reliability, more uptime, and better profit margins in the long run.

1. Monitoring Improvement

IIoT sensors provide 24/7 monitoring of critical equipment instead of relying on periodic manual checks. This can be especially valuable in collecting data from assets that are remotely located. Sensor alerts can be sent from scattered equipment and gathered in a centralized computer system.

2. Cost Savings

The price of sensors themselves have dropped significantly in recent years. Sensors also reduce labor costs in equipment monitoring. By triggering less expensive preventive maintenance tasks, sensors can reduce the amount spent on major problems or emergency repairs.

3. Integration Capabilities

Sensors data can be sent to a computerized maintenance management system (CMMS) for analysis. This allows maintenance managers to look at historic trends of particular assets, as well as pinpoint failure spots and frequency. This integration of data generates the information to make better future business decisions.

10 Popular Sensors Used for Industrial Automation

Hundreds of sensors are available for all sorts of industrial applications. Many of these fit in some general categories with specific sensors available for particular requirements. Here’s a short-list of the most popular sensors available today.

1. Vibration Sensors

Vibration sensors monitor the vibration levels of certain assets. Often, vibration can signal a potential failure that’s on the horizon. A maintenance technician can be deployed to check a piece of equipment that’s vibrating and make adjustments or repairs immediately.

2. Temperature Sensors

Temperature sensors usually ensure that an asset stays within a safe temperature range. This can prevent overheating of an asset like a boiler. In the food industry, it’s essential that products stay within a safe range in freezer or refrigeration equipment.

3. Proximity Sensors

These sensors help alert an operator when one piece of equipment is too close to another piece of equipment. One common application is within fleet vehicles. If a truck or forklift is about to hit something, a sensor will alert the operator before the collision occurs.

4. Gas Sensors

These sensors can alert the maintenance crew if smoke or another unwanted gas leaks into an area. In the case of dangerous gases, this addition can make a significant contribution to the health and safety of employees.

5. Security Sensors

Security sensors can be placed near key windows and doors to monitor motion in those areas. If a company requires high security levels, security sensors can help detect unwanted visitors.

6. Humidity Sensors

Depending on the sensitivity of nearby equipment, a facility may need to monitor surrounding humidity levels. An acceptable range can be set, and when levels fall out of range, alerts can be immediately sent.

7. Pressure Sensors

During installation, a maintenance technician can set the maximum pressure allowed for a particular asset. If the equipment exceeds that pressure, that asset can be automatically set to shut down as a safety precaution. A work order can then be issued to perform the repair.

8. Level Sensors

These sensors can monitor the level of a particular fluid in a piece of equipment. When low levels threaten an asset’s performance, an alert can be sent so fluids can be refilled. In addition, level sensors can measure powder or other materials, even trash in a dumpster, to prompt a maintenance action.

9. Infrared Sensors

These sensors emit or detect infrared radiation or measure released heat. Infrared sensors can help monitor things like blood flow in health care applications or remote control signals.

10. Theft Sensors

Used frequently in retail, theft sensors can be attached to valuable items to ensure they stay within an acceptable location. Facilities may attach theft sensors to expensive tools or other items prone to disappear.

Industries that Need Industrial Sensors

A wide variety of industries can benefit from using industrial sensors. Businesses focused on agriculture and healthcare require equipment and asset monitoring. Manufacturing, fleet management, and oil and gas facilities can also employ sensors to keep track of machine performance.

Agriculture

Businesses in the agriculture sector typically use IIoT sensors to monitor a wide variety of equipment. Sensors can assist with weather stations, irrigation equipment, and crop machinery.

Healthcare

IIoT sensors can help healthcare organizations monitor not only equipment and inventory but staff and patients as well. Many medical industries use IoT devices to monitor patients' overall health and vital signs. In some cases, this information can be sent to a healthcare provider for long-term care and treatment.

Manufacturing

Manufacturing facilities can use a wide variety of IIoT sensors to monitor assets and equipment as well as production lines. In some cases, machines can be programmed to automatically shut off when sensors reach thresholds to prevent breakdowns, expensive damages or accidents.

Fleet Management

Whether you’re operating a fleet of vehicles, trucks or forklift machinery, sensors can help you keep track of everything effectively. Sensors that reach particular mileage or usage thresholds can signal the time for maintenance. Proximity sensors can ensure that machines do not collide with other vehicles or equipment.

Oil and Gas

Oil and gas rigs, pipelines and other equipment benefit from IIoT sensors that can detect leaks and track assets. In addition, alerts can be triggered if any number of measures fall out of safe ranges, calling for preventive maintenance as needed.

How Industrial Sensors Work With Your CMMS

When sensors note that certain thresholds or conditions have been met, they send data to a cloud for processing. The information is transmitted to your CMMS for further analysis and to provide a foundation for smart business decisions.

Step 1: Sensors Report Data

Sensors are attached to critical assets, thresholds and ranges are set, and monitoring begins.

Step 2: Data is Uploaded to Cloud

The data is being constantly sent to the cloud for processing.

Step 3: Data is Processed

Software then determines if thresholds are exceeded or performs more complex analysis.

Step 4: Data Appears on CMMS

The information is finally transmitted to the company’s CMMS for reports, further consideration, or as a basis for future business decisions.

Conclusion

Industrial IIoT sensors will play an increasingly important role in a wide number of industries over the next decade. The cost of the technology continues to drop while the cost savings, safety improvements, and production benefits will rise. Finding the right sensors to monitor your most critical assets will provide you with a wealth of data. This will then serve as your foundation to an effective and efficient predictive maintenance program.