Top IoT Sensors for Predictive Maintenance
Since Alexa has started taking commands from users, the world has seen the practical use of IoT clearly. But today, IoT is not limited to just your home network.
The market for IoT is sky-high. As per the Markets and Markets report, the global IoT market size is expected to hit the $650 billion mark by 2026.
These numbers are huge, and the sole reason for them is the widespread adoption of IoT backed by the Industry 4.0 revolution. Manufacturing, telecom, automobiles, and logistics are industries that are slowly adopting this technology. With the use of IoT, these industry sectors have uncovered numerous benefits, including predictive maintenance solutions.
What is Predictive Maintenance?
Just like its name suggests, predictive maintenance is a method that uses data analysis tools and techniques to analyze the condition of a machine and suggest improvements and countermeasures before any major damage happens. The process involves the analysis of present and past data to suggest solutions.
Several technologies work in sync with each other in predictive maintenance, such as Artificial Intelligence, Machine Learning, Integrated Systems, etc. Some of the prime examples of predictive maintenance are oil analysis, thermal analysis, thermal imaging, etc.
What are the Benefits of Predictive Maintenance?
Sensors like temperature sensors, pressure sensors, and vibration sensors play a pivotal role in the effective working of the IoT network and, consequently, the predictive maintenance process. Here are some of the chief pros of predictive maintenance!
Reduces maintenance and overall cost
When it comes to the utility of IoT, the primary reason why businesses, like manufacturing, logistics, etc., are adopting it is the cost savings. As per statistics, unplanned downtime costs industrial manufacturers close to $50 billion a year.
With the use of IoT sensors and predictive maintenance, manufacturers can save on this cost, including the maintenance cost and the overall cost. They can plan maintenance drives way before equipment damage occurs. Thus, extending the equipment’s life and reducing labor costs.
- Boost production capacity
The next role of IoT predictive maintenance solutions is production capacity. With the IoT sensors in place, you can get real-time equipment details that can help you keep the machines running for an extended period without any downtime. Hence, this will automatically boost the production capacity of your production plant.
2. Improves equipment lifespan and uptime
With the use of predictive maintenance backed by IoT sensors, you can directly improve the lifespan of the equipment. As you get the sensor data, you can analyze any abnormalities in the data and take care of the issue ASAP. This will help you boost machine uptime and lifespan.
As an example, in logistics, the fleet of vehicles can be fitted with IoT sensors that can be monitored to get information about the engine, transmission, and more. Based on the information analysis, the required measures can be taken before time runs out to prevent permanent equipment failure.
3. Enhances labor utilization
With predictive maintenance, you can manage your workforce better. As it becomes easier to spot and resolve issues before any damage occurs, you can plan the tasks for your workforce in advance. Hence, you can use your labor in an efficient manner.
4. Increases efficiency
When you use predictive maintenance backed by IoT, you can significantly reduce manual inspections and maintenance tasks. This allows the technicians to focus on more important tasks, like major repairs to damaged equipment. thus enhancing the overall process efficiency.
5. Prevents accidents
With the use of predictive maintenance, you get to know about the equipment’s health before anything bad happens. This allows you to repair it before it reaches its last stage and worsens. As the equipment may fail catastrophically at its end stage, predictive maintenance can save you from potential accidents, if any.
Top IoT Sensors for Predictive Maintenance!
Just like IoT, predictive maintenance is linked to almost every industry. Therefore, almost all kinds of sensors are used for predictive maintenance. Here is a brief elaboration of the top IoT sensors used for predictive maintenance solutions.
- Pressure sensors
Pressure sensors are primarily used in industries that deal with water, oil, and gas. These sensors can be fitted in pipes and tanks that store or transfer fluids and gases. In case of any leak or blockage in the pipe, the pressure sensor indicates a change in the value, and the concerned authority is sent a warning message.
2. Gas sensors
A gas sensor is used to detect multiple gases in the air. These sensors are a prime part of the oil and gas industry and are primarily used to detect toxic gases. Besides industries, these sensors also have home applications as indoor air quality monitoring devices.
3. Temperature sensors
These sensors are one of the most commonly used in the industry. Temperature sensors come in handy to measure the temperature of equipment like motors, gears, piping, etc. As there is a chance of overheating in these types of equipment, temperature sensors can provide proactive warnings before any damage happens.
Temperature sensors are also used in the agriculture and manufacturing sectors today.
4. Humidity sensors
Some industries require zero moisture in the air, such as smartphone manufacturing. Hence, humidity sensors can come in handy. These sensors detect the presence of moisture in the air. Some humidity sensors can also tell you the amount of water in the air. They are ideal for HVAC systems.
5. Vibration sensors
Vibration sensors are used to monitor the intensive vibrations of heavy machinery. These sensors measure vibrations above a certain threshold and send a warning signal to the equipment’s controller. These sensors are a primary part of the heavy industry’s motors, compressors, gearboxes, and fans.
6. Proximity sensors
If you have ever received an offer message about a product that you just visited in the store, it is the magic of a proximity sensor. The proximity sensor detects the presence of objects near it without any contact. It happens with the help of electromagnetic radiation. The prominent use of proximity sensors is seen in retail stores and places like malls and stadiums.
7. Security sensors
This is a broad category of sensors that are used to ensure security. For example, security sensors can be a collection of motion detectors, alarms, GPS trackers, infrared sensors, photoelectric beams, etc. All these sensors can be used individually or in combination to ensure top-notch security.
All these sensors are part of the IoT infrastructure. If you want to buy these sensors, there are numerous producers, such as NXP, Excelitas, Renesas, Amphenol, Murata, Omron, Texas Instruments, and more.
Conclusion
One thing is sure, predictive maintenance solutions are the future of industries, and they heavily rely on IoT sensors. IoT sensors are of numerous types; each industry requires all or a subset of them. After reading so far, you must have picked up on the idea of IoT sensors. Therefore, it will be easier for you to pick the right set of sensors for your business processes.
