Overview of main industrial sensors: guide to selection and implementation

SensorsIIoTMaintenance

Practical guide to selecting and implementing the most common industrial sensors: temperature, vibration, and current. Focus on selection criteria, installation, and integration to maximize return on investment.

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Elements

  • Data acquisition system compatible with industrial protocols
  • Reliable industrial network (wired or wireless)
  • Monitoring and analysis software
  • Adequate electrical infrastructure
  • Calibration and maintenance plan

Core technologies

  • Temperature sensors (thermocouples, PT100, infrared)
  • Triaxial vibration sensors
  • Non-invasive current transformers
  • Industrial data collection gateway
  • Alarm and notification system

Results

  • 35% reduction in unplanned machine downtime
  • 25% increase in machinery lifespan
  • 15-20% energy savings
  • 40% reduction in maintenance costs
  • Average ROI in 12-18 months for standard installations

    • Sensor selection criteria

    Sensor selection is based on four fundamental criteria. For temperature, consider the operating range, required precision, and installation environment (direct contact or distance measurement). For vibrations, evaluate sampling frequency, sensitivity, and environmental resistance. For current monitoring, consider the measurement range, required precision, and ease of installation without service interruption. In all cases, compatibility with existing communication protocols and resistance to environmental conditions (temperature, humidity, dust) are essential criteria.

    Implementation and integration

    Implementation follows a structured three-phase process. The planning phase identifies critical measurement points and defines the necessary technical specifications. The installation phase includes correct sensor positioning, network configuration, and measurement validation. The integration phase includes configuring the monitoring system, defining alarm thresholds, and training personnel. Particular attention is paid to initial calibration and defining a periodic maintenance plan to ensure measurement reliability over time.

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