“Reliable smart sensors are the foundation of predictive maintenance. By capturing key performance data (changes in temperature, vibration, position, pressure), manufacturers can better understand the condition of their machines, reducing potential risks. Receiving real-time information allows them to see trends and react quickly to avoid failures that can lead to costly and disruptive downtime, while keeping employees safe.
This article is compiled from todaysmedicaldevelopments
Reliable smart sensors are the foundation of predictive maintenance. By capturing key performance data (changes in temperature, vibration, position, pressure), manufacturers can better understand the condition of their machines, reducing potential risks. Receiving real-time information allows them to see trends and react quickly to avoid failures that can lead to costly and disruptive downtime, while keeping employees safe.
As factories undergo digital and automated transformation, the need for equipment to prevent these problems and enable proactive maintenance is increasing dramatically. As demand grows, and as more and more factories seek continuous production and efficiency, the expectations for sensors to be faster, more accurate, and more durable are growing.
Next-Generation Data-Driven Solutions
The need to capture multiple types of measurements in an extremely small package has driven the development of multi-sensing elements, such as TE Connectivity’s 830M1 embedded piezoelectric (PE) triaxial accelerometer. Monitor machine health with embedded inductive accelerators where wide bandwidth, small size, low power consumption, and robust performance are critical. The higher resolution of the accelerometer provides a long-term, stable and accurate reliable solution for industrial condition monitoring applications in harsh environments. Its fully hermetically sealed lead-free chip carrier (LCC) package enables sensors on the PCB to measure in a single package, rather than having to measure X, Y, and Z accelerations in three separate chips, reducing package size and cost cost.
Bjorn Ryden, Director of Product Management at TE, said: “These sensors provide you with endless data that not only helps your plant run 24/7, but also improves mechanical efficiency as parameters can be continuously adjusted online. By minimising downtime time to increase productivity and help address workplace safety issues.”
During development, TE focused on key parameters and design components to simplify continuous condition monitoring and provide information to guide better decisions to support operation in harsh environments. The core technology element of the 830M1 is internal piezoelectric sensing technology, which provides excellent frequency response, measurement resolution, long-term stability and minimal drift. Piezoelectric sensing requires no power supply and can provide signal conditioning (charge-to-voltage conversion) in devices with very low current requirements.
“It’s a reliable technology,” Ryden said. “The key advantage is the wide bandwidth or frequency response. Since the 830M1 offers up to 15kHz frequency response bandwidth, it also has excellent measurement resolution. It enables end users to determine high-speed applications. very early failures.”
The sooner shop workers spot a problem, the lower the cost of a repair program.
future sensor technology
Ryden predicts that Industrial Internet of Things (IIoT)-enabled factories will continue to be a major driver of sensor applications, making devices more accurate and durable. The end manufacturer will gain improved quality, visibility and production control.
Advances in sensor technology will also continue to make predictive maintenance more feasible and affordable. Easier installation, miniaturization and wireless sensing will continue to drive down costs. As factory floors become more connected, other devices and applications will require multiple sensors to fit into a smaller footprint. This will drive further miniaturization of sensors while also reducing power consumption requirements. Additionally, engineers will rely more on wireless solutions to retrofit existing equipment and achieve a high return on investment (ROI).
Another clear trend is increased sensor fusion. This includes using multi-sensor integration and connecting all devices on the factory floor to capture multiple types of measurements, creating robust, reliable data outputs.
“The 830M1 is actually a combination sensor. It’s a three-axis vibration sensor that also has a resistance temperature detector (RTD) that provides a temperature output.” Ryden added, “The end user can choose to read temperature and vibration from this sensor. Two indicators.”
Sensor fusion will accelerate as the IIoT becomes more secure, improving the secure transmission of critical data. This, in turn, will enhance remote operation capabilities.
There is a growing need for smarter sensors to process and interpret large volumes of data. The field is constantly evolving as we move into a more connected world.
Implementing artificial intelligence and machine learning on sensors is still in its early stages, but Ryden expects to see more shifts as the industry moves into the next phase of IIoT evolution.
“We see ourselves as critical to addressing this and the growing sensor fusion and artificial intelligence (AI) market,” Ryden said, “and we will continue to work with customers and with our ecosystem partners to address these challenges, develop next-generation sensors that meet these needs.”
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