Smart Sensors
How they impact skill requirements
for manufacturing industry workers
Industry 4.0 Enablers
In Industry 4.0, physical processes are seamlessly integrated with software and computational
processes into “cyber-physical systems”. Such systems typically involve intelligent sensing
technologies at the data measurement and monitoring level of the system architecture. Smart
sensors provide operators, technicians, and engineers with real-time, meaningful information to
increase productivity, efficiency, and flexibility of the manufacturing sector.
Sensors have been around factories and plants for a long time; they evolved throughout industrial
revolutions thanks to developments in electronics and material science.
Schematic Representation and Key Functions
Smart sensors are regular sensors with an embedded microprocessor that allows processing directly
within the sensor package to provide additional functions and connectivity.
Industry 4.0
Industry 3.0
Industry 2.0
Industry 1.0
Input: Energy Form
Smart Sensor
Memory
Sensor
Modulator
Data
Conversion
Electrical Sensor
Ability to record
signal
Electronical Sensor
Web integration
and data exchange
Smart Sensor
Data aggregation
and processing,
system
integration
Tight Integration with Industrial Networks
Industrial Ethernet
Fieldbus
IO-Link Connection
Transmit data
to master devices
Predictive
Maintenance
• Self-monitoring,
calibration, and
diagnostic
• Real-time monitoring
• User-friendly data
visualization
Smart
Functions
• Decentralization of
processing
• Efficient processing
• Data storage
• Power management
Widespread Use of IO-Link Technology
IO-Link is a communication protocol that expands fieldbus and industrial Ethernet systems. It makes
communication with sensors simple and economical, the main reasons for its popularity.
Industrial communication networking standard (IEC 61131-9)
PLC
IO-Link Masters
Main Characteristics
• Short distance
• Bi-directional
• Digital
• Point-to-point
• Wired/wireless
• International
• Open
• Fieldbus-independent
IODD files are listed
in the IODDfinder
database
Transferred Data Types
• Process data
• Value status
• Events
• Device data
IO-Link Device Description
Each IO-Link sensor has its
own IODD file, to be uploaded
to a configuration tool for
easy parameterization.
IO-Link Master
IO-Link
Smart Sensor
IoT Gateway
IO-Link Master
Local User
Interface
Improved
Communication
• Flexible
manufacturing
• Fast commissioning
CP System / IoT / I4.0 / Big Data
IO-Link
Devices
IO-Link
Master
Fieldbus
IoT
Smart sensors make the data collected and processed available through all layers of the network
(machines, PLCs, SCADA, MES, ERP, Cloud) using a communication protocol.
Enhanced
Performance
• Various setting
possibilities and
operating modes
• Multipurpose
sensors
• Fault compensation
Data
Transmission
Perform
predefined
operations
Take input from
the environment
Mechanical
Transducer
Indicator without
electrical output
Microprocessor
and Application
Programs
Output: Processed Data
Evolution of Sensors
IO-Link Device Communication
Device Identification
Table
IO-Link Sensors and Actuators (Slaves)
Device
Variable
IODD.xml
Device
Process Data
Device Application
IODD File Structure
Essential Skills in Industrial Communications and IT
Working with smart sensor technology involves more skills than working with regular sensors. A thorough understanding of the advantages and characteristics
of smart sensors, in addition to the development of new abilities, is necessary to reap their full benefits.
Select the right
smart sensor for
the right
application
Set up IO-Link
communication
Define
parameters of
predictive
maintenance
Parameterize,
monitor, and
adjust smart
sensors
Integrate
sensors into
industrial
networks
Troubleshoot
and replace
sensors, and
upload settings
Especially important for:
Mechatronics/electrical/maintenance/IT/
process control technicians; automation
and control specialists; industrial
electricians.
References
- Fundamental Principles of Smart Sensors, Festo Didactic. 2019 Edition.
- www.researchgate.net/publication/325048285_Sensors_40__Smart_sensors_and_measurement_technology_enable_Industry_40
- www.nap.edu/read/4782/chapter/4#17
- http://link.springer.com/chapter/10.1007/978-1-4302-6014-1_3
To discover our sensor technology
learning solutions, visit:
This infographic was created by Festo Didactic SE in March 2020. All rights reserved.
www.festo-didactic.com