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What are common challenges in selecting and calibrating sensors for industrial control?

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Sensors are essential components of any industrial control system, as they provide the feedback information that enables the controller to adjust the output variables according to the desired setpoints. However, selecting and calibrating sensors for industrial control is not a trivial task, as it involves several challenges and trade-offs that affect the performance, reliability, and cost of the system. In this article, we will discuss some of the common challenges in selecting and calibrating sensors for industrial control, and provide some tips and best practices to overcome them.

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Sebastián Trolli

Global Head of Industrial Automation & Software at Frost & Sullivan | Driving Business Growth via Industry Analytics…
Balaji R

1 Sensor specifications

When selecting sensors for industrial control, one of the first challenges is to ensure that the sensor specifications match the requirements of the system and process. This includes considering the range, resolution, accuracy, response time, linearity, and robustness of the sensor. The range should cover the full input variable without exceeding its limits or losing accuracy. The resolution should be able to detect small changes in the input variable without being affected by noise or quantization errors. The accuracy should measure the input variable with minimal deviation from the true value, without systematic errors or drifts. The response time should be quick to react to changes in the input variable without introducing delays or overshoots. The linearity should have a linear relationship between the input and output variables without exhibiting hysteresis or nonlinearity. Lastly, robustness should enable the sensor to withstand environmental conditions and disturbances without compromising its functionality or durability.

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Sebastián Trolli

Global Head of Industrial Automation & Software at Frost & Sullivan | Driving Business Growth via Industry Analytics, Market Research and Consulting | Industry 4.0, AI, Digitalization, Data-Driven Manufacturing | Speaker
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Two of the most significant challenges are: 1- Ensure sensor specifications align with system requirements, including considerations of range, resolution, accuracy, response time, linearity, and robustness. 2- Sensor drift and noise pose demand meticulous and very accurate calibration methods for precision. Furthermore, the integration of smart sensors in Industry 4.0 requires advanced calibration techniques for optimal monitoring and control.

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2 Sensor selection

When selecting sensors for industrial control, it is essential to compare and evaluate the different types and models of sensors available in the market, and choose the one that best suits the system and the process. Compatibility, cost, availability, and maintainability are all factors that need to be taken into account. The sensor must be compatible with the controller, actuator, and communication protocol of the system without any additional hardware or software modifications. Additionally, it must fit within the budget and economic feasibility of the system without compromising quality or performance. Furthermore, it should be easily accessible from the supplier without causing any delays or shortages. Finally, it should be easy to install, operate, and maintain without frequent calibration or replacement.

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Carl Lee Tolbert, PhD, CMRP

Leading Voice in Industrial Systems & AI | AC Drive Performance & Reliability Expert | Published Research Scholar | Social Media Exponent | Lecturer
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I mentioned this in another post regarding the selection influences of components (including sensors) as a function of asset management during the preliminary stages. Obviously, the specifications of the sensors are driven by the application (or should be). The challenge is what decides between brands of similar designs. If two sensors do the same function, then why does it matter, one may ask. But what if one is superior from a performance or reliability perspective? The usual response would be to choose that one, but in reality, it is not so clear based on brand performance, history, or relationship with the seller, be it a distributor or rep.

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3 Sensor calibration

A final challenge in selecting and calibrating sensors for industrial control is to guarantee that the sensor output is consistent and precise throughout the system's operation, without being affected by external factors or internal changes. To ensure this, a calibration procedure should be followed that follows safety and quality guidelines, and is conducted using appropriate equipment and methods. Additionally, the sensor should be calibrated at regular intervals that adhere to the manufacturer's recommendations and the system's specifications. After each calibration, it is important to verify the sensor using independent and reliable measurements, comparing the results with expected values and tolerances. Finally, the sensor calibration should be recorded and stored properly, providing relevant information and data.

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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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Balaji R
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We used to consider below criteria 1. Right selection of sensors based on the application and sensing range 2. Ensure right Types - proximity (npn or pnp) inductive/ capacitive/ Diffusor sensors, inclination sensors / Programmable sensor/area scanners or vision cameras / GOM cameras or spot sensor / light curtain or barriers / touch probes …etc 3. Easy accessible locations and faults troubleshooting to maintain for any loose wirings or locking/ firm fixing (Periodic maintenance) 3. Availability (local markets & less lead time) and cost effectiveness 4. If it is under PLC / CNC - scanning cycles and auto calibration controls during machine building 5. Proper guards to avoid and damages and prevent from all Sources of contamination/damages

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What are common challenges in selecting and calibrating sensors for industrial control?

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1 Sensor specifications

2 Sensor selection

3 Sensor calibration

4 Here’s what else to consider

Control Engineering

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