Types of Industrial Sensors: Manufacturing, Automation, IoT, & More

The more we rely on electronic technology, the more we need extra eyes and ears to keep the world safe and running.

Sensors are critical data-collection points for companies and users, enabling devices to read and react to their surroundings.

This functionality is central to modern “smart” technology, including industrial automation and manufacturing processes. Heavy-duty sensors turn physical inputs into electrical signals, which are then processed by systems to produce something valuable to society.

Depending on what your operation produces, a highly specific type of industrial sensor may be the answer. Best to learn now what your team needs for smooth takeoff!

Click to Skip to a Sensor Type:

What’s an ‘Industrial’ Sensor?

With all the conditions and scenarios that require a sensor these days, it’s just about impossible to list every type here. Position sensors alone have four subtypes, one of which has six sub-subtypes of its own. 

Don’t let your eyes glaze over worrying about how many different types of sensors there are. Instead, review what exactly qualifies as an industrial sensor. There are informal distinctions between “industrial,” “commercial,” and “residential” sensors based on expectations for performance and material makeup.

• Residential sensors – Use standard battery power and plastic. Don’t require complicated connectors, typically relying on a micro-USB or USB except when waterproof or airtight conditions are a must (i.e. kitchen use).
  
  
• Commercial sensors – Require a degree of sensitivity, but typically don’t face tough environments. Tend to come with a lower price point than industrial sensors due to less stringent federal requirements.
  
  
• Industrial sensors – Must endure harsh conditions in factories and outdoor environments. Offer the ultimate precision for use in high-priority control processes. Usually need to meet strict safety and performance requirements (IP, ATEX, IECEx, etc.).
  
  

Types of Industrial Sensors by Function

Industrial components have quite the job role. They do their work in demanding environments, yet must be precise and – like the name implies – sensitive.

The most common way to identify product types is by the following:

As you can imagine, different types of industrial sensors serve different needs and markets. Some focus on efficient operation, while others must keep safety risks in check.

Temperature & Humidity Sensors

Machines and electronics must keep their cool in the line of duty. As such, industrial temperature sensors are one of the best indicators of a system’s health.

A temperature sensor collects data about heat level and interprets it in a way that another device can understand. Like UPS, temperature sensors must be reliable across air, water, and ground (under soil).

The main benefit, of course, is prevention of overheating (or freezing, in certain cases). With the right temperature readings, your system can:

• Run efficiently
• Avoid system failures
• Preserve battery & other component lifespans

Similarly, an industrial humidity sensor (aka hygrometer) can measure the moisture in the air, whether inside or outside. In industrial situations, they’re about more than just creating a comfy and energy-efficient room. Humidity sensors also control air quality and reduce the risk of degradation or contamination in:

• Food processing
• Pharmaceuticals
• Cleanrooms

The main criteria for choosing a moisture sensor model are response time, sensitivity level, and repeatability.

Some multipurpose sensors help with temperature and humidity. Thermo-hygrometers are a worthwhile purchase where both conditions are a threat, such as:

• Data centers
• Industrial processes
• HVAC systems
• Greenhouses
  
  

Motion Sensors

This is probably the most famous and visibly obvious example of a sensor. When a deer or an adventurous house cat causes an outdoor light to turn on, that’s motion sensing in action.

Industrial motion sensors convert movement from a “field of view” into an electrical signal, which can then function as an input.

Cats aside, motion sensors have a few key functions that help prevent major losses. You don’t need us to explain building security to you. But what about heavy-duty machinery? Wiring a motion sensor to a shutdown switch could prevent disaster in the case of a worn-out bearing or an operator sticking his hand in harm’s way.

The type of sensing solution you install can have major cost and safety implications for the assembly and its user.

That’s why context matters. Think of your sensor purchase as one of two subcategories: local sensing or area sensing. As usual, the application and end-use environment will dictate which solution you need.

Position Sensors

Consistency is the mother of automation.

Imagine a production line or inspection station where everything is out of place. The automated equipment has no point of reference, the robotic arm keeps missing the widget it’s trying to pick up, and potential defects are going unnoticed.

Industrial-grade position sensors help tie together processes so machines – and humans – can work more efficiently. If equipment or workpieces needs to be in a precise location, position sensors are your solution. They determine the presence, or lack thereof, of a target by watching for distance, direction, or speed.

Common uses for position sensors include:

• Automotive
• Material handling & logistics
• Robotic manufacturing
• Medical & lab

A common way to separate types of position sensors is by their measurement method – rotary, linear, or angular. 

Data measurement itself also has multiple categories: static and dynamic. Make sure the sensor you select takes the right kinds of measurements for your application.

Static position data is for a stationary object. In industrial systems, you’d use this when precision positioning is a must for assembly, inspection, or calibration. 

Dynamic data involves measurements of moving objects, either in intervals or continuously. It helps inform real-time applications like car navigation and the movement of automated machinery.

Pressure & Force Sensors

Pressure and force sensors do very similar jobs, though technically they’re two different measurements. Force measures a push or pull, both in magnitude and direction. Pressure only  measures the magnitude of force across a surface.

Pressure sensors are one of the most common types in manufacturing, particularly in maintenance. These devices use a pressure-sensitive subcomponent to output a signal that assesses whether flow pressure is higher or lower than normal. If the reading is too far beyond normal levels, the sensor will trigger a warning. 

In conduits for liquid and gas, use of pressure sensors can alert operators to the need for maintenance, whether scheduled or unplanned. This results in more uptime and the ability to fix small issues before they become big, costly ones. 

Force sensors (aka force transducers or load cells) have nearly the same job description, except that they detect mechanical pressure. As a force physically presses into the sensor’s strain gauge, it creates an electrical signal that takes the form of a readable value.

Industrial-quality force sensors are an essential tool in high-precision products and high-risk systems.

In some such industries, both pressure and force need a constant babysitter to ensure system integrity.

These are just a few examples. Precise measurement of force and pressure is critical to safety, product quality, and operational efficiency.

Vibration Sensors

Not all vibrations are good. So many pieces of industrial equipment use rotating parts that it’s practically impossible for an operation to stay upright without vibration sensors. (For long, at least.)

It’s all in the name of predictive maintenance.

Acceleration, velocity, and displacement data is useful for tracking the consistency of vibration in a machine. If the readings show predictable vibration, the equipment is probably working correctly. If there are huge peaks and valleys, the machine might need maintenance.

Vibration sensors team with personnel to provide, understand, and act on even the smallest jumps in activity. This allows the team to schedule fixes far in advance instead of having to endure a longer shutdown when a catastrophic failure happens.

Flow Sensors

The flow of liquid or air is an essential measurement in a surprising number of industrial processes. Flow sensors (aka flow meters) check the rate or quantity of a substance that passes through a pipe or system. These sensors can also give information about the pressure and temperature of the fluid or gas.

As the backbone of many automation processes, flow sensors improve:

• Quality control – Detection of variations in flow, allowing immediate corrections to prevent product defects or inconsistencies
• Efficiency – By monitoring flow, users can adjust valves & pumps to minimize waste and energy use
• Safety – Can identify blockages, excessive pressure, and leaks that could cause machine damage, spills, and accidents

In many operations, precision trumps power. Industrial flow meters are important to safe production in industries like:

• Water & waste treatment
• Energy & power
• Food & drink
• Paper
  
  

Level Sensors

Can you make it to the grocery store on that last bit of gasoline?

Level sensors gauge, monitor, and help maintain the amount of material inside a certain space. The material is often water or another fluid. The “certain space” is usually a container such as a tank, silo, or vessel.

No matter the material or container, the benefits of this technology can be huge:

• Efficiency – Real-time data allows for automatic refilling or draining, keeping the operation continuous while reducing waste
• Quality control – Can detect unwanted interaction between two materials, safeguarding their purity
• Safety – Removes the risk of overflows or critically low levels that could lead to equipment failures, spills, injuries, & regulatory noncompliance

There are two classifications of level sensors:

• Point-level – Indicates when a substance is at a certain amount
• Continuous-level – Measurements of a substance’s rises and falls

Continuous-level sensors have become the more popular type in the 2020s because they provide more granular data.

Common uses of level sensors include:

• Automotive
• Manufacturing
• Appliances
• Energy & power
• Health care & pharmaceutical

Some level sensor applications have overlap. When choosing a product, match it wisely to the substance you’re measuring and the type of feedback your process requires.

More Electronic Component Education

As you can see, electronic sensors are touching nearly every market. From automation and marketing sensors to industrial IoT sensors, there’s a nearly endless supply of types and subtypes to learn about.

Of course, that’s true about many other types of electronic parts, too. To source the right parts at the right time for the right application, keep learning with our free e-book: