Innovative technologies with the Internet of Things at the forefront have revolutionized industrial companies, transforming how they perform and operate.
Remote monitoring, reduced asset downtime, better production, and prolonged equipment lifespan are just a few humble benefits you can reap by leveraging industrial IoT software (IIoT). To make the most of these advantages, IoT sensors kick in. They play a pivotal role in realizing your business goals.
In this article, we’ll explore the role of IIoT sensors and their key types and discuss the potential pitfalls you may encounter during implementation. Let’s dive in.
Read an in-depth guide about Industrial IoT Sensors
What is the role of sensors in industrial IoT?
At their core, IIoT sensors measure various conditions like temperature, humidity, and vibration and transmit this data to central systems for in-depth analytics.
As such, these devices become precious for industrial firms, enabling the collection of real-time insights and making it possible to harness issues early on. Moreover, industrial sensors offer remote control capabilities, allowing entrepreneurs to respond to issues from a distance.
For example, in cold chain monitoring, IoT sensors can help ensure the required temperature of perishable goods during transportation and storage. In case of any predefined temperature changes, you’ll receive a notification and may take immediate action to preserve product quality and minimize waste. Thus, noticeably improving overall operational efficiency.
What are the top industrial IoT use cases?
IIoT has been successfully leveraged across various industries. Therefore, this innovative technology serves as a powerful tool for businesses of all sizes and niches. Now, let’s tap into the top 5 most prominent use cases of the Industrial Internet of Things.
1. Proactive Maintenance
As the saying goes, “Prevention is better than cure.” IIoT solutions provide proactive maintenance by offering real-time data to track device conditions and forecast potential issues.
In this context, the industrial Internet of Things has become a powerful tool that empowers manufacturing systems. By installing sensors on your equipment, you can monitor vital parameters like vibration and temperature. If there is any deviation, you’ll be promptly notified.
As a result, you may both prevent issues early and extend the lifespan of equipment.
Discover more IoT Use Cases in the Manufacturing
2. Asset Monitoring and Tracking
The Internet of Things has significantly enhanced asset monitoring and tracking. With a solid solution in place, it is possible to optimize routes, reduce delivery times, and ensure the safety of sensitive product shipments.
By employing wireless devices like GPS or radio-frequency identification tags, you may track shipment locations and monitor crucial conditions like temperature and humidity. This reduces the likelihood of lost shipments while maintaining product quality throughout transit.
3. Energy Management
Another prominent use case of IIoT sensors is efficient energy consumption. In particular, current monitoring devices detect anomalies, optimize energy usage, and minimize waste.
As such, you can not only cut electricity costs but also promote environmentally friendly approaches to sustainable energy practices.
Explore the transformative potential of IIoT for Sustainability
4. Industrial Automation
Automation is at the heart of various industrial applications. There are many ways to leverage this innovative tool in your solutions. For example, it is possible to employ automated guided vehicles (AGVs) in warehouses for goods transportation. AGVs can efficiently manage the movement and storage of products.
As a result, you’ll reduce manual intervention, lower staffing costs, and significantly decrease the likelihood of errors.
5. Retail Optimization
Though we often take personalized customer experience for granted, achieving it is a challenging task. But you may bring it to life by implementing IoT in your retail solutions.
Here is how it works: IoT sensors monitor buyers’ movements in the store, providing insights into their preferences and shopping habits. These data help optimize product placements and offer targeted promotions.
Furthermore, the Internet of Things is a valuable tool to ensure the consistent availability of popular items. Specifically, IoT sensors monitor inventory levels, enabling proactive stock adjustments. This reduces the risk of losing potential clients due to stockouts.
Check more uses of IoT in Retail
What are the major types of sensors which are used in industries?
Depending on your business niche and the degree of manufacturing controls and automation you require, there are different types of sensors to consider. Here are some prominent ones to keep an eye on:
Temperature Sensors
The name speaks for itself — these devices are designed to measure and monitor temperature. Typically, they are used for a variety of reasons, from monitoring house temperature to ensuring food safety and quality during pasteurization and transportation.
Humidity Sensors
These types mostly complement the previous ones to ensure product quality. On top of that, humidity sensors are valuable assets for manufacturing facilities. In particular, these devices help measure factors such as product degradation, mold growth, and equipment corrosion. Thereby, fostering product quality and operational efficiency.
Vibration Sensors
These ones rapidly warn technicians of equipment faults or damaged parts that require immediate replacement. It assists in minimizing breakdowns, as well as ensuring the safety and longevity of the machinery.
Pressure Sensors
At its core, these sensors aim to detect the rise and fall of pressure. They can be utilized for different purposes.
For example, if you operate in the automotive industry, you may leverage pressure sensors to create innovative products such as smart tires. It will assist in monitoring tire temperatures and pressures leading to better vehicle safety and performance.
Discover how Velvetech developed a Revolutionary Smart Tire Product
Speed Sensors
If you need a solution to ensure machinery functions properly, speed sensors will do the trick. They monitor the direction and speed of a spinning shaft and can quickly alert you to any anomalies. Moreover, these devices are smart enough to shut down the machine immediately upon detecting a problem. Thus minimizing wear and giving time to address the issue.
Check how we developed Torque and Speed Sensors for an Engineering Company
Anti-Theft Sensors
These devices are the best for safeguarding your property. Anti-theft sensors can be utilized in various environments, such as retail stores, warehouses, or apartments. This flexibility makes them among the most versatile IoT sensors available.
What are the key considerations for integrating IIoT sensors into existing systems?
Having discussed so many advantages of IIoT sensors, you probably feel motivated to put them into practice. But before that, we suggest considering the most common pitfalls you may face during the implementation. Check them out to be fully prepared for uncertainties.
- Sensor failures: Even smart technologies fail sometimes. And ensuring uninterrupted operation for continuous data flow and efficient operations can be challenging.
- Security: Businesses rely on interconnected devices and sensors to collect and transmit sensitive data, which can put private information to cyber threats.
- Scalability: As your operations grow, you may require expanded sensor networks. Hence, it is important to ensure that the infrastructure can handle additional devices and data without compromising performance.
- Cost: IIoT sensors are not a cheap pleasure. Beyond the initial acquisition costs, it is crucial to consider budgeting for setup, ongoing operational expenses, potential replacements, and other relevant factors.
- Environmental conditions: Depending on where you place sensors, environmental noise can pose a challenge. It can distort the signals devices detect, thus compromising overall operational accuracy.
How do IIoT sensors leverage other technologies like AI and machine learning?
Industrial IoT sensors do not rely solely on themselves to enhance business operations. They smoothly employ other advanced technologies, with AI and ML leading the way.
In general, AI and ML lie almost at the corner of each use case we have discussed above. Let’s explore some vivid examples of these cutting-edge technologies in industrial Internet of Things sensors.
Anomaly Detection
Artificial intelligence is a powerful tool for detecting abnormal behavior. For example, AI algorithms can analyze sensor data to identify unusual patterns in energy consumption, helping pinpoint potential equipment drawbacks and harness energy inefficiencies.
Data Analyses
Typically, you handle vast amounts of data to optimize your operations. Artificial intelligence plays a crucial role in collecting and analyzing these insights. AI algorithms not only reduce human errors in data analysis but also aid in forecasting patterns. Thus, enabling data-driven decisions.
Customer Unique Experience
IoT apps leverage machine learning to provide personalized user experiences. For example, with this advanced technology, you can have a smart thermostat that adjusts your home’s temperature and humidity according to your preferences.
Wondering how it’s possible? Quite simply, ML algorithms detect your habits and environmental conditions to ensure the most comfortable atmosphere for you.
Quality Control
ML can be highly beneficial in product quality monitoring. Sensors collect data on the temperature and chemical composition of goods, and ML analyzes this data to identify deviations from quality standards.
Take a look at more cutting-edge uses of Machine Learning in IoT
We’ve briefly touched upon just a few examples of how ML and AI shape the industrial Internet of Things. However, we are sure it’s clear that these technologies have a profound impact on IIoT sensor capabilities.
Understanding the importance and benefits of IIoT sensors, many industries have actively incorporated them into their solutions.
There are plenty of sensor types to consider. However, it’s crucial to ensure you choose the proper one or a couple that can be valuable assets in your endeavor. Otherwise, replacing an irrelevant device can cost a fortune.
Velvetech has proven expertise in delivering successful industrial IoT solutions and can assist you every step of the way. Contact us, and we’ll help implement sensors that best match your solution’s needs.
