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How can you ensure sensors and actuators in your industrial control system resist environmental factors?

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Sensors and actuators are essential components of any industrial control system, as they provide the interface between the physical process and the controller. However, they are also exposed to various environmental factors that can affect their performance, reliability, and accuracy. How can you ensure that your sensors and actuators can resist these factors and deliver optimal results? In this article, we will discuss some of the key aspects to consider when selecting, installing, and calibrating your sensors and actuators for your industrial control system.

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1 Sensor and actuator types

The first step is to choose the right type of sensor and actuator for your specific application. There are many types of sensors and actuators available, each with its own advantages and disadvantages. Some of the common factors to consider are: the range, resolution, sensitivity, linearity, response time, accuracy, repeatability, and robustness of the sensor or actuator; the type, magnitude, and frequency of the input or output signal; the compatibility with the controller and the communication protocol; the power consumption and supply; and the cost and availability of the sensor or actuator. You should also consider the environmental conditions that the sensor or actuator will be exposed to, such as temperature, humidity, pressure, vibration, noise, dust, corrosion, radiation, etc., and select the ones that are designed to withstand them.

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Johnny Broughman

Data Center Facility Manager at Amazon Web Services
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The one thing I did not see in this list is redundancy, which is a large portion of operational control especially in sensitive/critical environments. If you find that a sensor will need to exist in an area where you cannot afford to lose visibility, it’s important to make sure you have a fallback!

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2 Sensor and actuator installation

The next step is to install your sensors and actuators in the appropriate locations and orientations. The placement of your sensors and actuators can have a significant impact on their performance and accuracy. You should follow the manufacturer's recommendations and best practices for the installation of your sensors and actuators, and avoid any sources of interference, distortion, or damage. For example, you should avoid placing your sensors and actuators near heat sources, electrical devices, magnetic fields, or moving parts that can affect their readings or operations. You should also ensure that your sensors and actuators are securely mounted, properly aligned, and adequately protected from mechanical shocks, moisture, dust, or other contaminants.

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3 Sensor and actuator calibration

The final step is to calibrate your sensors and actuators regularly. Calibration is the process of comparing the output of your sensor or actuator with a known standard or reference, and adjusting it if necessary to ensure its accuracy and consistency. Calibration is important because sensors and actuators can drift, degrade, or malfunction over time due to aging, wear and tear, environmental changes, or other factors. By calibrating your sensors and actuators, you can ensure that they are operating within their specifications and providing accurate and reliable data and control signals to your controller. You should follow the manufacturer's guidelines and procedures for the calibration of your sensors and actuators, and use appropriate tools and equipment. You should also document and record the calibration results and dates, and schedule regular calibration intervals based on the expected lifetime and performance of your sensors and actuators.

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Johnny Broughman

Data Center Facility Manager at Amazon Web Services
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One very commonly missed factor in calibration is the digital to analog conversion. Sometimes, using HART communication for example, you’ll see the output as 4.13mA but the actual is 4.17mA, this is an a perfect zero and span which leaves the operator standing there scratching their head. The D/A converter is responsible for this output and can be calibrated independently of the sensor. Think of how many inputs/outputs are being processed in a large industrial operation that, when all factored together, may have a collective error that is fairly large due to this!

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Johnny Broughman

Data Center Facility Manager at Amazon Web Services
(已编辑)
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One very commonly missed factor in calibration is the digital to analog conversion. Sometimes, using HART communication for example, you’ll see the output as 4.13mA but the actual is 4.17mA, this is at and otherwise perfect zero and span which leaves the operator standing there scratching their head. The D/A converter is responsible for this output and can be calibrated independently of the sensor. Think of how many inputs/outputs are being processed in a large industrial operation that, when all factored together, may have a collective error that is fairly large due to this!

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4 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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How can you ensure sensors and actuators in your industrial control system resist environmental factors?

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1 Sensor and actuator types

2 Sensor and actuator installation

3 Sensor and actuator calibration

4 Here’s what else to consider

Control Engineering

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