Sensor Types and Applications
Understanding different sensor types helps you select the right devices for your monitoring requirements.
Environmental Sensors
Temperature and humidity sensors monitor climate conditions critical for equipment operation and personnel comfort. Air quality sensors detect particulates, gases, and VOCs for health and safety compliance. Light sensors enable automatic lighting control and energy optimization. Noise sensors monitor sound levels for occupational safety and environmental compliance.
Equipment Sensors
Vibration sensors detect machinery anomalies indicating potential failures. Current sensors monitor electrical consumption and identify efficiency issues. Pressure sensors track hydraulic and pneumatic systems. Flow sensors measure liquid and gas throughput in pipelines and processes.
Safety and Security Sensors
Motion and occupancy sensors detect presence for security and energy management. Door and window sensors monitor access points. Water leak sensors prevent damage from plumbing failures. Smoke and gas detectors provide life safety monitoring.
Placement Planning
Strategic sensor placement maximizes monitoring effectiveness while minimizing installation and maintenance costs.
Environmental Monitoring
Place temperature sensors away from direct sunlight, HVAC vents, and heat sources. Position at heights representative of occupied zones (1.2-1.5m for personnel areas). Multiple sensors may be needed in large spaces to capture gradients. Consider thermal mass effects near walls and windows.
Equipment Monitoring
Mount vibration sensors directly on equipment bearings or motor housings. Use appropriate mounting methods (magnetic, stud, adhesive) based on surface and vibration levels. Position current sensors around phase conductors per manufacturer specifications. Ensure adequate clearance for sensor maintenance.
Coverage Optimization
Map sensor coverage areas to identify gaps and redundancies. Consider worst-case scenarios when determining detection range. Plan for future expansion by including spare capacity in network infrastructure. Document sensor locations in facility drawings for maintenance reference.
Connectivity Options
Selecting appropriate connectivity ensures reliable data transmission from sensors to your monitoring platform.
WiFi Connectivity
WiFi sensors work well in areas with existing network coverage. Verify signal strength at planned sensor locations. Consider dedicated SSID for IoT devices with appropriate security. Battery-powered WiFi sensors may have limited life due to power consumption.
LoRaWAN
Long-range, low-power protocol ideal for large facilities and outdoor deployments. Single gateway covers several kilometers depending on environment. Excellent battery life (years) for battery-powered sensors. Lower bandwidth suits periodic environmental readings.
Cellular (LTE-M/NB-IoT)
Operates on cellular networks without local infrastructure requirements. Ideal for remote sites or mobile deployments. Consider ongoing data costs in total cost of ownership. Coverage depends on carrier network availability.
Wired Connections
Most reliable option for critical monitoring points. Ethernet provides power and data (PoE) in single cable. RS-485 supports long cable runs for industrial sensors. Higher installation cost but lower ongoing maintenance.
Installation Process
Following proper installation procedures ensures reliable sensor operation and accurate readings.
Pre-Installation Checks
Verify sensor firmware is current before installation. Test sensor operation on bench before field deployment. Confirm connectivity and data transmission to monitoring platform. Document sensor serial numbers and assigned identifiers.
Physical Mounting
Use appropriate hardware for mounting surface and environment. Ensure weatherproof enclosures for outdoor sensors. Position cable entries downward to prevent water ingress. Allow adequate space for maintenance access and battery replacement.
Commissioning
Configure sensor parameters (sampling rate, thresholds, units). Verify readings against known reference values. Configure alert thresholds based on operational requirements. Document as-installed configuration for future reference.
Quality Assurance
Verification procedures ensure your sensor network provides accurate and reliable data.
Accuracy Verification
Compare sensor readings against calibrated reference instruments. Environmental sensors should read within specified accuracy (typically +/-0.5C for temperature). Document calibration results and schedule periodic recalibration. Flag sensors with drift for investigation or replacement.
Connectivity Testing
Verify consistent data transmission at expected intervals. Test during various conditions including peak network usage. Confirm data appears correctly in monitoring dashboard. Establish baseline signal strength for comparison during troubleshooting.
Documentation
Create installation records including location, configuration, and calibration data. Update facility drawings with sensor locations and cable routes. Provide operations team with sensor inventory and maintenance procedures. Establish change management process for sensor modifications.
