Industrial Sensors: Selection Criteria

Sensors represent one of the fundamental elements of modern industrial systems. From factory automation to energy systems, from electric mobility to working machinery, the ability to detect and monitor physical parameters is essential to ensure efficiency, safety and operational continuity.

Temperature, pressure, position, level, humidity and air quality are just some of the variables that must be monitored in real time to enable the correct operation of machines and plants.

The selection of the right sensor directly affects the reliability of the data collected and the overall performance of the system.

Correctly defining the parameter to be monitored

The first step in selecting a sensor consists in precisely identifying the physical quantity to be detected.

Among the most common applications:

• temperature monitoring;
• pressure measurement;
• position sensing;
• fluid level control;
• humidity monitoring;
• air quality detection;
• speed and motion control.

Each application requires specific technologies and different selection criteria.

An accurate definition of the measurement objective makes it possible to identify the most suitable solution from the early stages of the project.

Measurement accuracy and reliability

Not all applications require the same level of accuracy.

In some cases it is sufficient to detect a threshold value, while in others it is necessary to continuously monitor values with high accuracy.

During the selection phase it is advisable to evaluate:

• measurement accuracy;
• repeatability;
• long-term stability;
• sensitivity;
• response time.

These parameters directly affect the quality of the data collected and the system’s ability to make correct decisions.

The importance of environmental conditions

Sensors often operate under highly varying conditions.

Temperature, humidity, vibration, dust and chemical agents can significantly affect device performance and service life.

For this reason it is essential to consider:

• operating temperature range;
• IP rating;
• vibration resistance;
• compatibility with chemical agents;
• installation conditions.

A solution suited to the application environment helps to reduce failures and improve operational continuity.

Integration with control systems

A sensor must be able to communicate correctly with the system that will use the collected information.

The selection must therefore also consider aspects related to electronic integration and communication.

Among the elements to evaluate:

• output type;
• power supply;
• compatibility with PLCs and controllers;
• communication protocols;
• ease of installation.

A proper integration helps to simplify the design and reduce development times and costs.

Sensors and predictive maintenance

The growing adoption of Industry 4.0 and the Industrial IoT has expanded the role of sensors within industrial plants.

Today these devices are not only used for process control, but also to collect data for predictive maintenance and performance optimisation.

Continuous condition monitoring in fact makes it possible to identify anomalies and degradation signs before they turn into critical failures.

This approach helps to increase plant uptime and reduce maintenance costs.

Applications across industrial sectors

Sensors are used in a wide range of application fields.

Among the main ones:

• industrial automation;
• robotics;
• automated machinery;
• HVAC systems;
• energy and storage;
• automotive and e-mobility;
• medical devices;
• agricultural and earthmoving machinery.

Each sector has specific requirements that influence the selection of the most suitable technology.

Solutions for industrial monitoring

Selecting the right sensor requires a comprehensive assessment of the application, considering simultaneously the parameters to be monitored, environmental conditions, accuracy requirements and integration modes.

To obtain reliable data over the long term it is essential to choose devices engineered to ensure stability, accuracy and resistance to the operating conditions typical of the industrial environment.

Among the solutions available on the market, specialised manufacturers such as Amphenol Sensors develop technologies dedicated to monitoring temperature, pressure, position, level and air quality for industrial, energy, automotive and off-highway applications.

The evolution of automation systems and connected architectures makes the availability of reliable sensors capable of supporting advanced control, monitoring and predictive maintenance strategies increasingly important.

Conclusions

Sensors represent the starting point for collecting reliable information and for the correct operation of modern industrial systems.

An accurate selection makes it possible to improve process control, increase operational efficiency and support advanced maintenance and diagnostic strategies.

Clever supports designers, OEMs, machine builders and system integrators in selecting the most suitable sensing technologies for specific application requirements, providing specialised technical expertise and access to leading international manufacturers in the sector.