Overview of Advanced IoT Sensors for Enterprise Digital Transformation

Over the past decade, many statistical agencies and IoT companies have predicted stable growth in the IoT market. Looking ahead, the IoT market is expected to experience even greater growth. According to Fortune Business Insights, the global IoT market is projected to reach a total value of $1,854.76 billion by 2028. The growing demand indicates that many business sectors have an increasing need for IoT solutions. More and more companies are integrating IoT solutions to meet their business needs, resulting in a surge in market demand.

The author of this article has been helping various companies achieve complex business goals involving integrated IoT solutions while working at PSA. Now he wants to share his practical experience and observations in the IoT field, unleash the potential of IoT sensors, and help enterprises choose the right sensors.

Sensors are referred to as “objects” within the IoT ecosystem. Therefore, in the following text, we will often refer to them as “objects”. Objects can collect information from enterprises, such as data from factory equipment to predict when failures may occur; they can gather data on external objects and personnel detected in specific areas; and they can also collect data describing working conditions, and so on. Once these data points are collected, they become the foundation for analyzing company performance, assisting companies in developing new business strategies, optimizing resources, improving productivity, and enhancing corporate safety.

The latest report from Mordor Intelligence confirms the manufacturing industry’s demand for IoT sensors, also known as m2m (machine-to-machine) sensors, indicating that the sensor market is expected to grow at a rate of 24% annually by 2026. To remain competitive in this market, manufacturers need to develop more practical, affordable sensors that can operate under various conditions. Therefore, we can see improvements in the reliability, working range, response time, performance, durability, integration complexity with other devices, and interoperability of sensors.

Compared to other components of the IoT ecosystem, sensors are not complex devices. They can measure various information, such as the temperature, sound, and vibration of machines. Unlike ordinary sensors, “smart” sensors can not only measure physical quantities but also process information, communicate with other devices, and make decisions. Additionally, they are faster, more accurate, and can even consume less power. Smart sensors typically use the following components:

• The sensor itself collects data

• The microprocessor generates data output

• The wireless communication function sends the output to a designated network location

Factories implementing Industry 4.0 solutions need to use smart sensors to provide the above measurements under more complex working conditions. For example, they can monitor moving objects, use ultrasound to measure the distance between themselves and areas that are difficult for workers to reach, and connect to equipment with potential hazards, thereby enhancing worker safety. Moreover, smart sensors can now perform many functions that only complex devices could execute previously. They can replace conductivity meters used to measure conductivity or TDS meters used to measure salt concentration. For instance, one of the projects we worked on at PSA involved using smart sensors in fuel distribution systems.

Advanced IoT sensors can be programmed according to the conditions of use. If necessary, factories can update the functionality of sensors to adapt to new working environments.

The most common types of IoT sensors in enterprises include:

• Pressure sensors can sense pressure changes in liquids and gases and measure the force per unit area

• Temperature sensors can measure the temperature of equipment or the environment and detect trends in its changes

• Chemical sensors can detect the presence of chemicals in the environment

• Motion sensors can detect the movement of physical objects

• Distance sensors can determine the distance between objects and themselves

• Water quality sensors can check for chemicals, oxygen, pH, and conductivity in water

• Smoke sensors can detect the presence of smoke in buildings

• Infrared (IR) sensors can measure levels of infrared radiation and heat

• Level sensors can measure the level of liquids, powders, and granular materials in certain tanks

• Image sensors can capture images for further processing and analysis

• Acceleration sensors can measure the acceleration of objects

• Gyroscope sensors can determine the direction of objects and measure their angular velocity

• Optical sensors can identify objects by detecting light reflection

Today, manufacturers of sensor solutions are focusing on the IoT field due to the demand in this market. Both startups and established companies may be interested in developing various sensor solutions. The IoT industry can benefit from their interest as sensor solutions become more practical, durable, and affordable. Deploying these sensors in enterprises is part of building the IoT ecosystem. At PSA, we have repeatedly seen this framework enable our clients to monitor all workflows in their companies at a glance.

So, let’s take a look at some of the most advanced sensor solutions considered in the IoT market.

Machine vision is often used in EIoT solutions, especially for quality control of products. However, these vision systems are not only complex but also quite expensive, making it more difficult for small companies to adopt them.

Today, as demonstrated by Denso, the aforementioned vision systems can be replaced by modern IoT sensors. Denso has developed the smallest stereo vision sensor on the market to be installed in cars to help prevent collision accidents. These vision sensors are implemented in smart cameras and can also be used for object recognition, manufacturing process control, and product quality assurance. Factories can install these small, practical devices in bulk to monitor numerous production nodes.

The sensor developed by Sick, called Visionary-T DT, can detect objects up to 160 feet away. It is a 3D video sensor that uses time-of-flight (TOF) technology to detect the presence of 3D objects. Solutions developed using this technology are candidates for ensuring corporate safety and protecting objects or areas. This sensor uses laser technology to capture images, providing you with high-precision 3D images in real-time. These sensors and cameras can be used to create highly accurate digital images, delivering optimal predictive results. This type of sensor is also easy to use in warehouses with robotic operations and can control access to various locations.

Complex devices used to measure current can also be replaced by compact sensors. Texas Instruments released some highly accurate current measurement sensors in 2020. They were among the first to utilize Hall effect current sensors, achieving minimal drift and high accuracy regardless of temperature conditions. These m2m sensors can operate under complex conditions ranging from -40 to 257 degrees Fahrenheit. High-voltage systems such as industrial motor drivers, solar inverters, energy storage devices, and power supplies can be easily equipped with such sensors, providing sufficient accuracy and safe monitoring conditions.

For industries like mining, construction, and automotive that place a high value on vertical tilt angles, the EIoT market also offers some innovations. Pepperl+Fuchs Vertrieb developed the F199 inclination sensor, which can measure angles with a resolution of less than 0.01° and an absolute accuracy of ±0.15°.

For dynamic inclination measurement needs, Murata Manufacturing has developed a new MEMS inertial sensor, SCHA63T. It is a single-packaged, six degrees of freedom (6DoF) component. This allows it to provide settings for all measurement axes, greatly simplifying the manufacturing process. Additionally, this sensor supports GNSS positioning. The device can provide centimeter-level accuracy in machine dynamics and position sensing, helping ensure safe, robust, and validated design activities.

When monitoring hazardous areas within enterprises, particularly areas where external personnel or objects should not exist, companies often use IoT solutions that include cameras, microphones, or GPS to ensure safety.

The Mimic Go sensor developed by Mimiq can detect environmental changes using an accelerometer, magnetometer, temperature data, and motion sensors that can recognize certain specific objects in that area. With it, you can obtain information about the nature of objects and detect potential threats to the production process. Once foreign objects are detected, the sensor immediately sends a signal to the production operator. Connecting this sensor with other IoT components can facilitate the identification of foreign objects and promptly address the corresponding issues.

Another impressive breakthrough last year was the development of battery-free sensors by Everactive. They have been deployed in Hershey’s factories, where their effectiveness has been proven. The company estimates that due to the extremely low power consumption of battery-free sensors, they were able to save thousands of dollars in steam system costs after two months of deployment. These IoT sensors meet most industrial measurement requirements, providing capabilities for temperature, humidity, light, vibration, acceleration, acoustics, pressure, and even various gas measurements. Furthermore, compared to battery-powered sensors, battery-free m2m sensors can be deployed on a larger scale.

Sounds like an industry-level breakthrough, right? Perhaps this battery-free technology will become the foundation for future EIoT—battery-free EIoT.

Sensors used in EIoT are equipped with next-generation chips, making them more advanced. For example, Qualcomm has released seven new chips to meet the needs of companies across various industries, providing them with new opportunities for visual monitoring of assets. Some of these chips support ultra-high-resolution cameras, as well as panning, tilting, and zooming activities.

The high-end chip named Qualcomm QCS8250 can be integrated into a sensor, allowing this sensor to activate robots operating in places like warehouses. What’s most impressive is how small the equipment required for these operations is.

Advanced chips can support resource-intensive IoT applications involving intelligent cameras, video collaboration, and AI centers. They can accomplish this through a new type of neural processing unit designed for ultra-intuitive AI and machine learning.

Even after determining their business needs, the process of selecting the right IoT sensors may not be as simple as it seems. Transforming a traditional factory into an Industry 4.0 enterprise requires consideration not only of the advantages of the sensors themselves but also of more practical aspects. Manufacturing companies should equip a large number of machines with sensors that operate under different conditions, perform different functions, and have varying depreciation levels. IoT products should help improve the efficiency of enterprises.

Do IoT sensors impact the achievement of a company’s business goals? There is no direct connection here, but we can establish the following chain between IoT sensors and business objectives:

Therefore, if a company wants to establish a robust business strategy, it should analyze the vast amounts of data collected by the sensors. If it cannot collect data accurately, then this strategy is not optimal compared to collecting data with the highest possible accuracy and will not be very effective.

To determine the qualities that m2m sensors in the factory should possess, you can first ask yourself the following questions:

• How much power does the sensor consume?

• Is it easy to install?

• How versatile is it in form and function?

• How much does it cost?

When selecting industrial sensors, pay attention to their physical reliability. It should be understood whether they are flexible enough to perform their functions in various environments. This means that the sensors should operate normally under various conditions, such as places with large temperature differences. Also, ensure that the IoT sensor platform is multifunctional, as it provides global interoperability for the sensors. Most importantly, make sure you apply the devices correctly.

After deploying sensors, you can provide corresponding protection against physical obstacles and electromagnetic interference, ensuring your wireless network has long-distance coverage and frequency hopping spread spectrum (FHSS) anti-jamming capabilities.

Next, determine the level of precision required for the sensors in the manufacturing process. For example, if the goal is to monitor temperature to ensure a comfortable working environment for factory employees, a slight degree of error is not a big issue. However, in a biochemical laboratory, even the smallest temperature change is critical to the process.

As part of the IoT ecosystem, sensors can transmit critical data that is strategically significant for the company. This means you should pay attention to their security, as hackers can access the entire system through a single sensor. Therefore, before introducing sensors into your IoT ecosystem, check their security and the encryption standards used for data transmission. To provide additional security, you can add a layer of authentication to the solution.

Additionally, it is important to understand how long the sensors can operate. If possible, find out how the performance of the devices changes over time and whether these changes depend on the working environment. You can also use the latest battery technologies (like solid-state batteries) to extend the lifespan of the devices. Sensors that only operate during data transmission activities typically require less power. In these cases, sensors can be battery-powered for over 10 years.

The last key point is that you need to include it in your budget. Sensors may be relatively inexpensive devices, but if you need to deploy an IoT ecosystem across the entire enterprise, you may need more than a hundred of such devices. Therefore, companies should be prepared to spend a significant amount of money on these “objects,” depending on the type of EIoT solution being implemented.

Furthermore, consider whether the sensors can be reused, what infrastructure they require during use, and how easy it is to maintain the operational conditions of the sensors.

No matter what you do, do not choose solutions that have not been tested within the company’s infrastructure.

Due to the rapid development of IoT, devices, including sensors, are becoming increasingly affordable, and the entire ecosystem is becoming smarter.

These results enable enterprises to obtain solutions tailored to their specific needs in manufacturing processes and measure information under complex conditions. For example, they can monitor the movement of objects, use ultrasound to measure the distance between themselves and objects that are difficult for workers to reach, and connect to equipment with potential hazards to provide data collection capabilities. Some complex, bulky measuring devices can be replaced by modern small sensors that can transmit data quickly.

Before deploying any IoT solutions (including sensors) to build an IoT ecosystem, PSA recommends that you identify all the flaws present in your current manufacturing processes and find solutions to address these issues.

At this stage, considering the many criteria that must be taken into account when selecting the best sensors, a reliable IoT partner can help enterprises identify all the details and formulate a deployment plan for the overall IoT ecosystem.

Author Bio:

Zach Prystash has extensive experience in developing go-to-market strategies in the EIoT field, having handled projects in industrial automation, healthcare, and fintech. He leverages his background and knowledge to help clients develop strategies and connect them with experts focused on building the future of EIoT. Since Pittsburgh has positioned itself as a global tech hub, Mr. Prystash has been closely monitoring the pulse of changing trends and striving to be a leader and a driving force.

Original Link:

https://www.infoq.com/articles/iot-sensors-enterprise/

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