The document discusses smart sensors for Industry 4.0, including their definition, classification, expectations from IoT, and examples like motion, light, thermal, and wind sensors. Smart sensors add intelligence, communication, low power usage and other properties to perform as IoT components.
The document discusses smart sensors for Industry 4.0, including their definition, classification, expectations from IoT, and examples like motion, light, thermal, and wind sensors. Smart sensors add intelligence, communication, low power usage and other properties to perform as IoT components.
The document discusses smart sensors for Industry 4.0, including their definition, classification, expectations from IoT, and examples like motion, light, thermal, and wind sensors. Smart sensors add intelligence, communication, low power usage and other properties to perform as IoT components.
The document discusses smart sensors for Industry 4.0, including their definition, classification, expectations from IoT, and examples like motion, light, thermal, and wind sensors. Smart sensors add intelligence, communication, low power usage and other properties to perform as IoT components.
Department of Instrumentation and Control Engineering
PRACTICAL NO: 03
AIM:- Smart Sensors of Industry 4.0
OBJECTIVES: 1. What is SMART Sensor?
2. Classification of Smart and intelligent Sensors.
3. Digital Transformation and centralized control in context of Industry 3.0
4. Drivers and Enablers of Industry 4.0. How everything is transformed in SMART?
RATIONAL IoT applications, whether for city infrastructures, factories, or wearable devices, use large arrays of sensors collecting data for transmission over the Internet to a central, cloud-based computing resource. Analytics software running on the cloud computers reduces the huge volumes of generated data into actionable information for users, and commands to actuators back out in the field. So, sensors are one key factor in IoT success. They have needed to evolve into something more sophisticated to perform a technically and economically viable role within the IoT environment like storage, communication and computation. Sometimes these capabilities of sensor recognized its perception and hence it accepted as intelligence sensors in situation of Automation as well as Industry 4.0.
Introduction
The word “smart” has been often applied to various sensor products and its meaning has been expanded by the continuous arrival of new and improved concepts in technology. The rapid improvements in the technology, including compactness and advanced microprocessor integration, make the range of sensor applications almost boundless. The smart sensor has intelligent capabilities such as wireless communication and being an on-board microcontroller. It is used for
24 | P a g e 3161716: Industry 4.0 Vishwakarma Government Engineering College Department of Instrumentation and Control Engineering analog to digital conversion, digital processing, decision making and two-way communications. Smart sensors have various advantages in comparison to conventional sensors such as smaller size, minimal power consumption, and high performance. What does the IoT expectation from Smart sensors? Sensors have traditionally been functionally simple devices that convert physical variables into electrical signals or changes in electrical properties. While this functionality is an essential starting- point, sensors need to add the following properties to perform as IoT components: Low cost, so they can be economically deployed in large numbers Physically small, to ‘disappear’ unobtrusively into any environment Wireless, as a wired connection is typically not possible Self-identification and self-validation Consume very low power, so that it can survive for years without a battery change, or manage with energy harvesting Robust, to minimize or eliminate maintenance Self-diagnostic and self-healing Self-calibrating, or accepts calibration commands via wireless link Data pre-processing, to reduce load on gateways, PLCs and cloud resources More advanced features: Information from multiple sensors can be combined and correlated to infer conclusions about latent problems. For example, temperature sensor and vibration sensor data can be used to detect the onset of mechanical failure. In some cases, the two sensor functions are available in one device; in others, the functions are combined in software to create a ‘soft’ sensor.
SMART Sensors Smart sensors are built as IoT components that convert the real-world variable that they’re measuring into a digital data stream for transmission to a gateway. Figure-1 shows how they do this. The application algorithms are performed by a built-in microprocessor unit (MPU). These can run filtering, compensation and any other process-specific signal conditioning tasks.
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However, the MPU’s intelligence can be used for many other functions as well, to reduce the load on the IoT’s more central resources. For example, calibration data can be sent to the MPU so that the sensor is automatically set up for any production changes. The MPU can also spot any production parameters that start to drift beyond acceptable norms, and generate warnings accordingly; operators can then take preventative action before a catastrophic failure occurs.
If appropriate, the sensor could work in ‘report by exception’ mode, where it only transmits data if the measured variable value changes significantly from previous sample values. This reduces both the load on the central computing resource, and the smart sensor’s power requirements – usually a critical benefit, as the sensor must rely on a battery or energy harvesting in the absence of connected power.
If the smart sensor includes two elements in the probe, sensor self-diagnostics can be built in. Any developing drift in one of the sensor element outputs can be detected immediately. Additionally, if a sensor fails entirely, for example due to a short-circuit, the process can continue with the second measuring element. Alternatively, a probe can contain two sensors that work together for improved monitoring feedback.
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Types of Smart Sensors
The classification of the sensors is done by referring the sources utilized for working. Major sensors called electrical one which broadly mapped as Resistive, Capacitive and Inductive type. Followings are the categories which is applicable to define Smart sensors
1. Electrical- (Resistive, Capacitive, Inductive and Frequency type)
The sensors are also identified by its size and shape
1. Mechanical type (vibration)
2. Electro-Mechanical type
3. Electro-Chemical type
4. MEMS- Micro-Electro Mechanical System
5. Semiconductor type (VLSI- Very Large Scale Integration Technology)
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Micro electro mechanical system (MEMS)
The major advantages of MEMS technology include minimizing energy and materials, enhanced reproducibility, improved accuracy as well as increased sensitivity and selectivity.
Very Large Scale Integration Technology (VLSI)
VLSI is the process of miniaturization of computer chips and implanting an emphatically large number of transistors gates on a single silicon semiconductor wafer. VLSI has many advantages such as reducing the size of circuits and the cost of the devices, increasing the operation speed of the circuit, less power consumption, while occupying a relatively smaller area.
Motion Sensors
Motion sensors are designed to detect people-presence when they enter or leave a space. When a motion is detected, the sensors send signals to trigger processes that increase or decrease power supply to light fixtures. Thereby, it automates the switching ON/OFF of lights and other in-house devices based on the occupancy/vacancy status of the assigned space. They can immensely save energy in commercial applications that deal with larger areas and people. These sensor-driven systems are also widely used in hospitals to monitor hand-hygiene compliance.
Fig.2: Animated working of Motion sensor
28 | P a g e 3161716: Industry 4.0 Vishwakarma Government Engineering College Department of Instrumentation and Control Engineering Light Sensors Tuning light to the time of day, month, or year is the prime functionality of light sensors. It automates luminaire functioning in smart buildings besides enabling human-centric lighting, daylight harvesting, and light scheduling for energy savings, efficiency, and ambiance.
Fig.3: Working of Motion sensor
Thermal sensors Automating room temperature in smart buildings and offices require thermal sensors. They maintain a constant internal temperature, no matter how the external temperature varies. These sensors also save energy by balancing the temperature in tune with the climate.
Fig.4: Different Arduino compatible Thermal Sensor
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Wind Sensors Smart buildings need to respond to nature smartly. Wind sensors automate the shutting down of dust skirts, storm shutters, or close retractable awnings if strong winds are detected.
Fig-5 Wind Sensor
Fig-6: Smoke Sensor
Smoke/Gas Sensors Smoke sensors ensure home or building safety, as they give instant alerts and trigger alarms in case of fire bursts. Thus, they drastically increase the chance to escape from accident scenes. Level sensors Level sensors are used for real-time measurement of containers, bins and tanks, feeding real-time information to inventory management systems and process control systems. They are used in everything from waste management to irrigation to diesel fuel gauging and more.
Fig-7: Water level(Depth) Sensor Fig-8: Wireless Gauge pressure sensor
Temperature sensors Temperature sensors are also very commonly used in industrial settings. Perhaps the simplest example is using temperature smart sensors to connect to a piece of machinery or industrial
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equipment. It is connected to and IIoT cloud computing platform and can detect when the machine or equipment is overheating and needs maintenance or to be shut down Pressure sensors Pressure sensors are used to monitor pipelines and alert a centralized computing system to leaks or irregularities that alert overseers that maintenance and repair is needed.
Fig-9: IR Sensor Fig-10: Proximity Sensor
Infrared sensors Infrared smart sensors are equally multi-purpose and are used across very different industries. They are used in medicine to track biological functions such as blood flow during surgery, they are used in architecture, engineering, and construction to monitor heat leaks in buildings and industrial facilities. They are also used in wearable for health and fitness. Proximity sensors Proximity sensors are used in retail to detect customer location and track crowd flow. Different retail outlets leverage this technology to ping the Smartphone of customers wandering around with coupons for deals on products that may be in their periphery. Position Sensors Position sensors operate on various sources of energy to detect proximate distance and presence of object if any. Common sources are light, Magnetism, changes in electrical values like resistance, capacitance and inductance. Gyroscope Gyroscope sensor is a device that can measure and maintain the orientation and angular velocity of an object. These are more advanced than accelerometers. These can measure the tilt and lateral orientation of the object whereas accelerometer can only measure the linear motion.
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Fig-11: Schematic of Gyroscope
Fig-12: Digital IoT based Gyroscope
Accelerometers An accelerometer is an electronic sensor that measures the acceleration forces acting on an object, in order to determine the object’s position in space and monitor the object’s movement. Acceleration, which is a vector quantity, is the rate of change of an object’s velocity (velocity being the displacement of the object divided by the change in time).
Fig-14: FASTag- RFID
Fig-13: 3-D Accelerometer
RFID tag RFID tags are a type of tracking system that uses radio frequency to search, identify, track, and communicate with items and people. Essentially, RFID tags are smart labels that can store a range of information from serial numbers, to a short description, and even pages of data.
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Fig-15: DHT11- Humidity/Temperature sensor Fig-16: FET Biosensor
Humidity/Moisture Sensors Humidity and moisture are the physical condition of specific environment. It can detect using resistive or other popular electrical method in the sensor operation. A resistive Humidity sensor will reduces its resistance proportional to environmental humidity and hence increases system conductivity. They dominated in the field of agriculture and its allied application Electro-chemical based FET sensors This one is one of the approaches to make popular biological event for detection of the information from the sample. These electronic sensors will change either its collector currents or saturated voltages when influences any changes of target parameter in the sample.
Conclusion:
Assignments: 1. What is Nano Sensors? Brief the contribution in Industry 4.0.
