Intelligent Sensors – Future of the Industry

Leuze India is getting a good footprint in the Indian Market and aiming to become a 100 Cr company by the end of year 2026. The contactless business is giving extra boost to sensors & Automation demand.

The first Industrial Revolution was marked in 1760 when man discovered the progress made using steam and water pressure. The second monumental progress was made when man understood the complexities of the assembly line and electric power. The most recent industrial milestone was made possible by computers and robots. Now, progress has dictated that the future of the industrial revolution is going to be propelled by SMART factories and IoT systems. The most crucial component that continues to make Industry 4.0 a possible reality is Intelligent Sensors.

Intelligent sensors can take input from the physical environment, analyse it using in-built computing functions to perform a predefined set of functions. The most basic example is the temperature sensor of an equipment. Based on the heat conducted, the temperature is continuously monitored. In heating, the sensor notifies the personnel to change the temperature or automatically triggers a function that can assist in cooling. Pick any factory, starting with the raw material analysis to the end loading of the packaging product and everything in between, like manufacturing of the product, quality testing the product and packaging of the product, employs various sensors. The first step to optimising operations and reducing faults and workplace hazards of any kind is installing the relevant sensors.

In recent years, the sensors have evolved to support the demands of tomorrow's consumers. Industries that work at the optimum condition and still can do while scaling will require intelligent sensors. In other words, intelligent sensors dictate the optimisation of operation industries today and their sustainability tomorrow.

Ways in Which Intelligent Sensors Propel Industries :
Redefining Operations & Process Control
Automation & cost-effectiveness is necessary for smooth operations and effective process control. Industries that are considered MSMEs tend to buckle down on maintenance and repairs to cut costs, which can have disastrous consequences in the long run. However, with the use of intelligent sensors, regularly scheduled maintenance is automated. More importantly, specific sensors can monitor all types of equipment and alert any personnel when the slightest damage occurs. This reduces downtime to a great extent and makes repairs genuinely cost-effective.

Scalability is crucial for progress. Whether gradual or sudden, increasing production capacity is a tedious task, wherein many parameters need to be redrawn, and several more variables need to be considered. However, using intelligent sensors like IO-Link masters and specific MD7 sensors provides a cost-effective solution for integrating sensors into the desired system, allowing the system’s expansion flexibly and economically. These sensors also offer great security.

Precision Monitoring
Consider vaccine manufacturing industries. Vaccines need to be manufactured at a precise temperature and need to be packaged thoroughly and safely. More importantly, sterility needs to be observed at all times and they need to be manufactured and packaged in large proportions. All of this is only possible if human error is eliminated. The best way to ensure that is by implementing a manufacturing site that is entirely automatic. In other words, using multiple intelligent sensors to monitor even the most minute infractions closely and immediately taking restitutive measures is vital. In vaccine packaging, special intelligent sensors like DRT25C.R unit pack sensor leverages CAT (Contrast Adaptive Teach technology) technique and uses a conveyor as a reference to detect various foil-wrapped bottle and can containers. This is crucial for monitoring the right containers and proper packaging is being done.

If one considers the food processing industries, then the composition of ingredients into each package needs to be precise. Intelligent sensors are the only components that can ensure that this process is executed at zero error. On the whole, monitoring is critical for quality, and the installation of intelligent sensors can guarantee quality.

Simplifying Automotive Manufacturing
In the common years, the automobile manufacturing industry is in for a complete overhaul. With rising climate change concerns, there has been a growing encouragement to shift from conventional automobiles to electric ones. This includes cars and heavy-duty industry vehicles. Safety is to be ensured and precision is key in every step - press shop, body shop paint shop, drive/powertrain: engine and engine assembly, battery and battery installation, and final assembly. This is possible with the help of intelligent sensors. Using smart sensors, the process can be automated, and manual errors can be significantly minimised.

Intelligent Sensors Make IoT Factories Hassle-free
SMART factories are where the future is headed. Reliable, intelligent sensors are essential to achieve seamless communications between various IoT components. For IoT to function seamlessly, large volumes of data need to be materialised and analysed; this can also be achieved using intelligent sensors. They are vital to identify objects, locate them, and generate data regarding their environmental conditions. This data needs to be populated from the beginning to the end of the process to create a big data pool, essential for the functioning of IoT components.

Consider the world’s tallest building, the Burj Khalifa. A monumental building was made possible because of the strong foundation provided. Similarly, the bolstering of industries today and tomorrow is entirely reliant on the effectiveness of intelligent sensors. Intelligent Sensors provide enterprises with the benefits of high reliability, minimal wiring expenses, reduced chances of wiring hazards, easy scalability options, and hassle-free use of equipment.

Every industrial innovation, SMART security system, SMART vehicles, SMART home appliances, or rather anything SMART, has been made possible due to the efficacy of intelligent sensors. More importantly, intelligent sensors are crucial to producing future innovations. This makes them true linchpins of Industry 4.0, and their impact on progress is truly unrivalled.