How Intelligent Sensors Are Revolutionising Everything
Published on : Sunday 04-09-2022
Future sensor technology and its development is the key to technological transformation in industry, says Jasbir Singh.
The concept of intelligent sensors is evolving over a period of time. Sensors which can sense, detect, capture information, process signals internally, understand the health of a machine or equipment and have communication capability to pass through by open protocol in a right format to the controller or final element of the loop. The intelligent sensor also has the ability to automatically schedule calibration, adjust, compensate and store/transmit the calibrated data for record. Intelligent sensor has the capability that determines its accuracy, resolution, stability and reliability, over the period it is in service. From the last two decades we see the improvements in the sensor’s physical size, features, intelligence and integration of technology. The size became more miniature, function of self-recognition and self-integration to network, high speed of processing and high internal memory for internal data processing function, execution of simple to complex algorithms, data storage capability, self-diagnostic, auto-correction to remain functional in the circuit for a long time.
The repeatability and accuracy are becoming highly stable over the period while the sensor is in use even in different environmental conditions. Properties of components used in sensors over the time of use, need to be compensated/corrected online to maintain its stability and measurement characteristic. The aging of components automatically gets compensated by adoptive technology for representing the true value of the measurement at scalable points for a longer period on its calibrated range. Self-health monitoring and correction by itself are the features that call for intelligent sensors by using its self-test, self-calibration and self-diagnosis capability, compensated periodically to maintain the accuracy and longevity of its precision use. Timely diagnosis of abnormalities due to the drift and deviation from correct value and precise measurement has been improved in intelligent sensors.
With the emergence of new digital technologies, the role of software in intelligent sensors has enlarged exponentially for quick connectivity, internal calculation, rapid data transfer, network communication, logical thinking and processing function. Advanced sensor technology evolving currently is extra focused on connectivity solutions having more scalable, higher bandwidth communication, larger volume data handling/transmission to the devices. Intelligent sensors in the first step acquire and collect data to process it for information conversion in the right format and carry out calculations in the next step, while in parallel, storing it in transient memory space. The calculated result internally is used for system control, and the information from here passes to the communication module for exchange and transmission of data to the final execution module, which is used for control instructions and system actions. The goal is to have low power consumption, reduced cost, and large range usage.
Addressable sensors
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The intelligent sensor with IP address is referred to as ‘IoT’ device (an addressable sensor) for process parameter measurement. These devices gather information and digitally communicate through wired/wireless networks with the network system. The system collects data from different devices to execute the logic at the cloud and indicate wirelessly through the dashboard to the operator. Applications executed from data through ‘IoT’ analytics, the information is shared to a defined address for specific data monitoring/control. The IoT devices are capable of providing information from specific areas, for necessary action in line automation, which automatically correct the deviation. Industrial IoT formally known as IIoT, connected with the Internet infrastructure used for monitoring and control, increases the feasibility/flexibility of accessing data/information from sensors in manufacturing plants to automate the system.
Characteristics of intelligent sensors
The following are the main characteristics of intelligent sensors:
i. High precision
ii. High stability
iii. High reliability
iv. High resolution
v. High signal to noise ratio
vi. Adaptive functional intelligent
vii. Autonomous self-test, self-calibration, self-tuning and self-diagnosis function
viii. Auto alive and configuration
ix. Storage and forwarding capability, and
x. Easy and remote updatable software.
The design of sensor technology is majorly inclined towards application-based development. For each application, a better technology and innovative design is emerging to use, such as an acoustic sensor in development that can recognise audio vibration or its frequency to determine location, activity, captivity and its intensity. Sensors being developed for chemical application are to measure fluid composition, concentration and its variation on a real time basis. In addition to application, the development of sensors is centred on miniature size, high speed communication and low power consumption. The development trend continues for miniaturisation, integration, and intelligence by having use of Artificial Intelligence (AI), Big Data, Internet of Things (IoT), and mobile communications such as 4G/5G. Breakthroughs in adoption of new materials, structures and processes are also seen in this decade. The technological innovation of intelligent microsystems uses the cutting-edge technologies using innovation of intelligent microsystems.
As IoT based measurement and cloud computation technologies grow, so does the sensor technology. The market accelerates on the merit of monitoring distant tags of scattered assets in the plant and where measuring parameters is difficult. Predictive analytics and the innovation of easy monitoring of data from a single platform across the geographical location is essential to manage operation. Computing capabilities of smart sensors have improved substantially, by enabling advanced data processing capability and its analysis at source. Intelligent sensors, security, trust and privacy advances in IoT, and are getting advanced day by day.
Progressive advancement in digitisation and its incorporation in sensors have a greater impact on costs, quality and manufacturing time. Demand for intelligent sensors is growing. Customers demand fast and reliable manufacturing of all sophisticated sensors for their applications. Future sensors become self-learning, which don’t need periodic maintenance, auto calibration and longer life span of its use and having safety features to predict unsafe situations. Requirement of more complex detection and multi variable data measurement is increasing. Intelligent sensors have well-integrated measuring modules which are easy to plug in and it has features to automatically adjust/calibrate to the application being used.
With the capability of signal processing internally it is shifted from hardware to software, which improves the measurement accuracy. No manufacturing variances are expected or it can be adjusted/tuned by a simple parameterisation correction. Mathematical models are used to understand the sensor behaviour or influence the effects for realising precise measurement.
Cost reductions and more improvement in accuracy and processing speed with sophisticated signal processing methods gives higher performance in new manufacturing technologies. Maintenance-free intelligent sensors having high integral processing functions, long life expectancy, low electric power consumption, and less heat generation are the focus of future development. The following features find more consideration during development.
1. Energy-efficient sensors are gaining significant attention among the wireless sensors because they do not require power connection and battery consumption is minimal. These sensors have wide applications in which no power source is needed. Power source even from nearby facilities or laying cable from long distances can be avoided.
2. The future intelligent sensor technology needs to have an integrated design to process the complex algorithm internally for advanced process control, adjust self-deterioration due to environmental changes and feedback in case of any abnormalities.
3. Long life expectancy and maintenance-free sensors find wider acceptance in process plants.
4. Flexible plug-and-play sensors are the important need to ease of connectivity like in built in drivers to recognise its presence shown live in the network.
5. Industrial automation sensors with AI integration tend to create revolutionary possibilities.
6. IoT sensor connectivity to the cloud through gateway and GPS connectivity are enhancing new openings for sensor application.
7. Sensor with small battery for self-powered and use of minimal power consumption while on real data execution and transmission function.
8. Intelligent sensors with a high level of interoperability for maximum flexibility.
9. Universal software platform/protocol for the automation of all hardware to be fit with the majority of process technology applications.
Digitisation in IoT improvements is a driving factor for the adoption of future sensor technology. Future sensor technology and its development is the key to technological transformation in industry, they’re supported by AI and cloud computing possibility in addition to fast Internet networks.
Jasbir Singh is an Automation Expert having long experience in Factory Automation, Line Automation, Implementation Strategist, Business Coach, Regular writer on automation, Artificial Intelligence, Robots/Cobots, Digital Technology, Network Communication, Industrial Internet of Things (IIoT), Wireless Communication, Block Chain and use of advance digital technologies. He has established a long association with Business Houses/large production houses to improve factory automation in their production lines as well as productivity improvement in factories in India and overseas; and in advising and designing the units to transform into digital platforms by use of Artificial Intelligence. Email: [email protected]
