The rise of environmental sensors in smart manufacturing

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The rise of environmental sensors in smart manufacturing



One of the largest areas for sensors in manufacturing is energy efficiency. Environmental sensors enable precise energy management by monitoring energy-relevant parameters such as temperature, pressure and power usage in data-rich, real-time modes. Source: pkproject/Adobe Stock

Environmental sensors are key enablers of real-time monitoring and decision-making in achieving desirable manufacturing outcomes.

Environmental sensors empower factories to operate smarter, cleaner and to make better products at lower cost. The transformative role of environmental sensors in effective manufacturing is often subtle and intricate in its application and influences, but manufacturers neglect the consequences of environmental impact on processes and equipment at their peril.

These sensors are used as tools in manufacturing to:Optimize energy use
Ensure specification and standards compliance
Enable precision and repeatability in processes

Rise of sensors

The integration of environmental sensors into manufacturing systems reflects a much broader shift toward Industry 4.0. Such sensors serve in monitoring a wide spectrum of parameters like temperature, humidity, air quality, noise levels, contaminant gases, radiation and particulate matter.

These sensors deliver a holistic view of a factory's operational environment.

Various factors have driven the widespread adoption of these sensors. First, increased regulatory demands have resulted in stricter environmental regulations that impose requirements on manufacturers to monitor and mitigate their environmental impact.

Second, sensors help to meet cost-efficiency goals for real-time data. This allows manufacturers to optimize processes and reduce waste and energy consumption.

Third, advancements in miniaturization and increasingly cost-effective sensors, combined with internet of things (IoT) connectivity, make widespread deployment both feasible and cost-effective. Finally, sensors assist in the demand for sustainable practices that is growing in popularity with vendors’ carbon net neutral goals.

Key applications

One of the largest areas for sensors in manufacturing is energy efficiency. Environmental sensors enable precise energy management by monitoring energy-relevant parameters such as temperature, pressure and power usage in data-rich, real-time modes.

This includes:Smart HVAC systems
Equipment monitoring
Air quality monitoring
Gas detection
Dust and pollution monitoring
Lighting optimization
Humidity control

A second key application is product quality assurance where environmental conditions impact the quality of manufactured products, particularly in the pharmaceuticals, food and beverage and electronics sectors.

These include:Temperature and humidity sensors for storage and processing
Cleanroom monitoring sensors for semiconductor manufacturing
Vibration monitoring detects slight machine/part motions

Predictive maintenance is another potential application where environmental sensors are pivotal in predictive maintenance strategies, providing data that helps to extend equipment lifespan and minimize downtime.

These include:Thermal imaging sensors for detecting overheating in motors, bearings or electrical systems.

Ozone sensors to monitor condition in switchgear.
Vibration and acoustic sensors serve to identify unusual patterns in mechanical systems.
Corrosion sensors to alert operators to conditions that promote corrosion.

Finally, environmental sensors in waste reduction and resource optimization contribute significantly to lean manufacturing operations.

These include:Material monitoring through weight sensors to track raw material usage and wastage.
Water quality sensors to monitor wastewater entering and leaving water treatment plants.
Emission control sensors to monitor and regulate gas and particulate pollutant emissions from manufacturing processes.

Case studies

In smart HVAC, automotive manufacturers with very large manufacturing facilities integrate temperature and humidity sensors into zone-controlled HVAC systems. Real-time data allows optimization of temperature settings across wide area facilities, reducing energy costs by 10% to 30% in most cases.

Chemical processing facilities deploy VOC sensors to monitor emissions, where real-time alerts from the sensors enable immediate corrective actions, reducing worker exposure to harmful chemicals and ensuring environmental regulatory compliance.

Electronics manufacturers use temperature and particulate sensors in their cleanrooms to maintain optimal conditions for processes such as chip-fab optical/chemical processing of wafers and assembling sensitive components, reducing defect rates to acceptable levels.

Some sensors in manufacturing monitor temperature and humidity in anything from a semiconductor cleanroom to an environmental control facility to lab quality control center. Source: Korngor/Adobe Stock

Challenges

While the advantages of distributed and networked environmental monitoring are clear, implementing environmental sensors in manufacturing is not without challenges.

The high initial investment can result from installing a network of sensors and integrating them into existing systems, imposing significant upfront costs. Combined with integration complexity, this can be a barrier, as sensors must be seamlessly integrated into existing manufacturing processes and IoT networks, which can create interface/communication challenges.

Meanwhile, data overload can arise from the vast amount of data generated by sensors, which can be overwhelming without proper analytics tools and wise selection of both sensor types and reporting intensity.

The final challenge would be the maintenance requirements of these sensors to deliver accuracy and functionality over time, which requires ongoing maintenance and calibration.
Looking ahead

A wide variety of factors are at play in the coming landscape of environmental sensing and its influence on Industry 4.0.

Microelectromechanical systems (MEMS) development is likely to improve sensitivity, accuracy and miniaturization of sensors for manufacturing. Also combining sensor data with AI is likely to enable predictive analytics, adaptive systems and deeper insights into manufacturing processes and the associated needs/consequences.

Edge computing of processing is likely to reduce latency and bandwidth requirements of implementing real-time sensors into manufacturing facilities. Wireless sensor networks eliminate the need for extensive and vulnerable cabling, making sensor deployment more flexible and cost-effective and reducing maintenance needs and potential disruptions.

Environmental sensors will play a critical role in creating and coordinating digital twins of manufacturing facilities to reflect the real-world, without which advanced simulation and optimization become disjointed and useless.

Conclusion

Environmental sensors are dramatically changing manufacturing processes and environments, by providing the data necessary for agile and informed, real-time decision-making. From energy efficiency and worker safety to product quality and regulatory compliance, these sensor systems enhance virtually every facet of industrial operations.

As sensor technology continues to evolve and their scope and remit expand, their integration with AI, IoT, and digital twin systems will unleash even greater potential for efficiency, sustainability and quality.

Manufacturers needing to stay ahead in a competitive and environmentally conscious market must invest in advanced environmental sensor systems.

Web Site : sensors.sciencefather.com

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