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Quick Introduction to Smart Sensors

You could have an overall understanding of sensors, such as what they do and why they are important, but smart sensors introduce an exciting and new angle. The manufacturing business, because of Industry 4.0, stands on the verge of a few very notable jumps forward since the introduction of steam power, and sensors are in many ways the center of it all.

Let us tell you what they can do to help your company and what these sensors are.

What Are Smart Sensors?

In past years, sensor technology was not able to achieve its entire potential because of other factors like latency power management and system noise. By these standards, any sensor working on a network with even modest edge computing capacities is considered a smart sensor. In comparison with previous generations of sensors, the low latency of modern IT infrastructure and the lower-power structure of newer, smarter sensors means manufacturers can exchange far larger quantities of data than ever before, across a wider area, with a larger number of peers, and execute more complicated evaluation of all that incoming data. In no time at all, it is going to be business-as-usual to set up sensors that could be the size dust particles with greater capabilities.

Even with their small, smart leverage onboard microprocessors they engage with relevant parties in instant wireless communication and can carry out on-site diagnostics. They provide additional functionality including:

  • Smart sensors facilitate smart automation by permitting the use of boundary conditions, which lowers the amount of low-level workers necessary to monitor machines and equipment.

  • Today, smart sensors are compatible with several major wireless protocols, including Wi-Fi, Z-Wave, Bluetooth and many others. Each one is suited to distinct targets and IIoT (Industrial Internet of Things) build-outs.

How Do Smart Sensors Affect Manufacturing?

The primary benefit of smart sensors in manufacturing concerns tracking hard areas or inhospitable conditions.

The variety of smart sensors makes it easy to put them within locations, dangerous equipment, and places. Inspecting equipment requires labor and time and doing so is not always safe or convenient. When the stakes are high, like batch of medications encountered with temperatures above or below the recommended limits, or when a specific device may have been knocked out of calibration in transit. Engineers can tell simultaneously or get alerts anytime when there is a problem. You can imagine how incredible it is to have this information at your disposal, and the decrease in losses associated to these risks.

Inhospitable places such as freezers and transport cartons, including some other places where having remote access to ecological and product conditions (humidity, temperature, speed, pressure etc.) comes in handy for monitoring the status of freight in transit or at rest. With the right supply of sensors, producers can get a sense of the health within the whole supply chain, from possible manufacturing flaws during production to the rate and condition where your products have been delivered to their users.

Smart sensors make it far more easy and cost-effective to warm, cool and otherwise maintain physical infrastructure. In the pursuit of achieving cost savings and decreasing environmental footprints, the manufacturing industry continuously uses sensors to help climate control and light. Smart sensors let facility lighting systems adapt based on how the space is being used. Lights and climate control may kick or turn up when someone enters the place, then when they are not needed, turn off again. It is a terrific way to realize energy savings so long as you remember to maintain recommended ambient lighting levels when your lights are on.

Also, smart sensors are used when setting up safety regulations during automation of certain tasks with robots. The sensors create an invisible fence around a designated area where a human may get injured if they get too close to the robot while it is operating. When activated the sensor will send a signal to the robot which will make it either reduce its speed or stop all together. This can dramatically reduce risk and increase productivity.


In this time of incredible technological advancement when manufacturers can create a true all-around view of their operations down to incredible detail, and smart sensors are playing a big role. Is there a bushing wearing out in one of your own machines or even robots? Now there is no waiting until failure to get the problem fixed!

Manufacturers who understand the benefits of smart sensors and utilize the IIoT to address problems that are pertinent in their business are the businesses which will stand prepared to compete in an international marketplace that has constant changes and the quick to adapt survive.

If you want more information on the smart sensors we offer and services we provide please reach out. We will be happy to help you!


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