Types of Industrial Sensors

Types of Industrial Sensors – A Sensor is a device that specifies the advancements in electrical, physical, or other portions and in a way has a product as an assurance of progress in the portion. In simple words, Industrial Sensors are information instruments that provide an outcome regarding a specific physical portion.

In Industrial Automation, the sensor plays a crucial role in completing the product’s intelligent and remarkably automatic. It allows one to notice, examine, calculate, and process a type of modification like alteration in place, length, height, surface, and dislocation that appear in Industrial manufacturing places.

Demand of Industrial Sensors in Indian Market –

Industrial sensors are essential in automation and manufacturing, ensuring process control and operational efficiency. In India, the demand for these sensors is growing due to rapid industrialization, technological advancements, and the rise of Industry 4.0.

The Indian industrial sensor market was valued at approximately USD 1.2 billion in 2023 and is projected to grow at a compound annual growth rate (CAGR) of 8.5% from 2024 to 2028.

Sector	Demand (%)
Automotive	30
Healthcare	15
Consumer Electronics	20
Energy and Utilities	10
Other Industries Ex – aerospace, defense, and food & beverage processing.	25

Types of Industrial Sensors for Industrial Automation-

There are different types of sensors for industrial automation according to different types of procedures and portions. These sensors are – 

Sensor Type	Description	Advantages	Applications
Temperature Sensor	Measures temperature and converts it to electrical signals.	Digital and combination temperature/humidity options.	Industrial process control, HVAC systems, weather monitoring.
MEMS Sensor	Microscopic sensors with low power consumption and high reliability.	Often integrated with wireless technology for automation.	Automotive, medical devices, consumer electronics.
Optical Sensor	Uses light for non-contact, high-speed measurement.	Remote sensing, object detection, industrial automation.	Object Detection and Counting, Remote Sensing, Machine Vision, Encoding and Positioning
Pressure Sensor	Converts pressure into electrical signals.	Monitors pipelines, leaks, and alarms for maintenance needs.	Industrial process control, hydraulic systems, medical equipment.
Proximity Sensor	Detects object presence without contact.	Non-damaging, long lifespan, works in harsh environments.	Assembly lines, robotic applications, safety systems.
Level Sensor	Monitors liquid levels in open or closed containers.	Provides continuous or point level measurement.	Inventory control, tank monitoring, chemical processing.
Flow Sensor	Measures flow rate of liquids and gases.	Used in various applications like industrial processes, automotive, and medical.	Different types for various flow characteristics (magnetic, vortex, turbine, etc.).
Infrared Sensor	Detects infrared radiation for object detection and measurement.	Non-contact, high accuracy, fast response.	Security systems, temperature monitoring, object counting.
Position Sensor	Determines position of machinery or objects.	Used in industrial process control, automation, and more.	Various types available (potentiometers, encoders, magnetic, etc.).
Smoke Sensor	Detects smoke for fire alarm activation.	Intelligent fire and smoke detection for safety.	Essential for fire-prone industrial environments.

Temperature Sensor –

In industries, Temperature is one of the most examined physical parameters and it is measured by different sensors. The temperature sensor is a device that grabs information about temperature from the atmosphere and changes it into defined values. There are two types of temperature sensors that are used in different aspects: Digital temperature sensors, and humidity &  temperature sensors. 

The Digital temperature sensor selection has a 10-digit dual-channel subsequent approx A/D converter and a standard RS-232 or 485 communication Surface. On the other hand, a humidity sensor is a combination of a temperature and humidity sensor. Generally, it is used as a temperature measurement element to manage humidity and temperature signals.

MEMS Sensor –

MEMS is a new type of sensor that is manufactured by using microelectronic and micromachining technology. They have small-size sensors that are used for low energy consumption, and high dependability and are suited for mass production. It is merged with ZigBee wireless technology to complete anthropomorphic dealings while working with machinery. 

Optical Sensor-

This sensor is based on the optic guide for measurement. It has too many advantages like non-contact and non-damaging measurement, no interference, high-speed information, remote control, etc. Optical sensors commonly contain an optical sensor and devices like general optic measure tools, laser interferometers, encoders, and fiber optics. It is generally used to detect the targeted object that appears or perform different industrial automation detection.

Pressure Sensor-

A pressure Sensor is an instrument that can perceive an indication and change the indication into a useful electrical signal considering a certain direction. It is commonly formed from a force-exposed element and a signal-processing unit. The pressure sensor is used to observe pipelines, leaks, and unnatural alarms in the computing system to remind industry supervisors that repair and maintenance are needed. 

Proximity Sensor-

The proximity sensor is a device that is used to examine the proximity of any object. This sensor uses the sensitive essence of the expulsion sensor to determine the closeness of the object and outputs the related switch motion. It can conduct non-contact sensing detection, so it will not do any damage, spark, or noise. This device has a long shelf life and rarely influences any service life of the contact. Proximity sensors are different from other detection techniques and suitable for work in an oily and water atmosphere and are hardly affected by these objects.

Level Sensor-

Level sensors are instruments used to observe, sustain, and estimate the level of liquids. When the liquid level is noticed, the sensor transforms the data into electrical alerts. A level sensor is a device used to choose the level of liquid floating in an open or closed procedure.

level measurement can be separated into continuous and point measures. A level sensor accurately calculates the liquid level, but the measurement result is correct. It is used to decide if the liquid level is high or low.

Flow Sensor-

Flow sensors are devices used to calculate the outpour rate of liquids and gases in industrial automation. It is generally used in many applications like industrial process management, automotive methods, and medical machines. There are different types of flow sensors that are – 

• Magnetic
• Vortex
• Turbine
• Coriolis
• Ultrasonic 

Infrared Sensors-

It is an instrument that operates infrared radiation to process data. Infrared radiation is also called infrared light. They have possessions including reflection, refraction, interference, and absorption. Any significance, if it has a specific temperature, can radiate infrared beams. This sensor is not in immediate contact with the calculated object during measure, so there is no conflict and it has the benefit of high acuity and fast reaction. An infrared sensor can observe the operation of the tool.

Position Sensor-

A Position sensor is a device that is used to examine and decide the position of machinery or objects in Industrial methods. It is generally used in a vast range of applications like industrial process control, industrial automation, and more. There are different types of Position sensors available in the market.

• Potentiometers
• Linear Variable Differential Transformers
• Capacitive
• Encoders
• Magnetic

Smoke Sensor-

A smoke Sensor can catch a large amount of smoke during a fire and send an alarm call in time. It uses MCU control, which can intelligently set fire and smoke during an alarm. A smoke sensor is an essential sensor in industrial automation inclined to fire and detonation. If smoke sensors are combined with the industrial Internet of Items solutions, even the smallest gas leaks or fires can be reported to the appropriate group, accordingly avoiding major tragedies.

Conclusion-

In Summary, the Industrial sensor is the heart of industrial automation or a smart industry. They provide real-time information, make decisions instantly & control several aspects of industrial procedures. Different types of sensors have different capabilities for various portions. Without industrial sensors, automation would not be possible and the safety & productivity of industries would be affected.