Sensors will play a critical role in the Industrial Internet of Things (IIoT) with machine condition monitoring and predictive maintenance data wirelessly communicated within the SMART factory. Position, speed, force, temperature, pressure, vision and vibration sensors are all playing vital roles in the robot's physical operation, providing the precision, endurance, speed and repeatability required.

There are 3 main types of robotics in Industrial IOT: Collaborative robots undertaking hazardous or repetitive tasks controlled via cloud computing can assist on the factory floor or on an automated production line working hand in hand with humans. Logistical robots automate the process of storing, moving, and packaging good safely but at high speeds within the warehouses operating 24/7. Industrial robots are automated, re-programmable and capable of movement in three or more axes, typical applications could be on an assembly line - welding, machining, painting, moving heavy materials, measurement & inspection and working in chemically harsh environments like a foundry.

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SMART buildings automate the processes to control the building's operations including heating, ventilation, air conditioning, lighting, security, water management and other systems. Temperature, humidity and pressure sensors are used in HVAC systems to maintain ideal building environmental conditions and can be used to detect failure or faults in the system too - like a clogged air filter. Too high humidity causes condensation which can cause some machinery to corrode within the building; controlling this is vital. Temperature measurement is also important in a building's water management system to reduce the spread of bacteria within the system, along with water quality sensors. RTD’s, NTC’s, thermopiles and digital temperature, and combined temp & humidity sensors, along with a multitude of pressure sensor are all used in these applications.

Environmental monitoring in buildings is a new hot topic where the air’s quality - particularly the CO2 levels - are monitored, higher levels are being experienced due to better insulated / sealed buildings, resulting in occupants getting headaches, feeling tiredness and being less productive. Room occupancy and people flow sensors such as PIRs, proximity, IR/ Time of Flight sensors are now being used to understand which spaces in a building are used most, or which meeting rooms are available, utilizing space effectively in large office builds can lead to large cost savings and increased productively. In museums, shops and supermarkets these sensors can also be used to understand marketing placement potential for a new product or exhibit. Motion sensors have been used in security detection for several years in the form of PIR sensors and contact sensors used on windows, doors, and secure cabinets. These devices are also now common for automatic door opening, hand dryers, toilet flushing, and to switch on and off lighting and heating, reducing energy consumption and running costs and essential for carbon neutral buildings. New security door entry systems are combining facial recognition (IR sensing/ cameras) and non-contact temperature sensing to ensure personnel entering the building are virus-free and healthy. For sure SMART Buildings are managed by a multitude of sensor technologies.

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With an aging and growing population, medical healthcare costs are a large burden to the taxpayers and governments, and the enablement of home healthcare is predicted to accelerate fast over the coming years to alleviate this problem. Patient diagnosis, monitoring, and treatment, also has other benefits in reducing a patient’s risk of exposure to infections, puts less stress on the patient, and allows them to recover in comfort of their own homes.  

Medical device manufacturers are developing wearable monitoring systems, these vital sign measurements can be logged into a home system and relayed wirelessly or via IoT to clinician hubs. In the event of an emergency a doctor/clinician can be notified to visit the home urgently. Typical sensors being used in medical devices include temperature sensors like thermopiles for non-contact temperature measurement, SpO2 sensors for pulse oximetry; for fall detection and activity tracking, sensitive pressure sensors can detect small changes in altitude determining a patient's position or to count steps taken in a day. Precision force sensors can be used to monitor weight fluctuations to determine if there are cardiac difficulties. Where a patient has dialysis equipment or infusion pumps, bubble detection sensors are used to ensure blood and fluids are flowing normally.

Home respiratory systems and sleep apnea devices will include airflow sensors, temperature, pressure, oxygen sensors and pressure switches to operate. In addition to Home Healthcare patient monitoring, sensors are used in automated laboratory equipment, surgical robotics and life support systems and medical apparatus within our hospitals.

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Sensors are multiplying in the world of transportation from automated agricultural equipment, to construction vehicles to e-buses, e-motorcycles and AGVs; electrification is the buzz word. The quest for reduced energy consumption to extend the vehicle’s range requires miniaturization and reduced weight. Battery management systems, electric powertrains, AC/DC and DC/DC convertors need to be smaller and lighter.

Sensors are aiding this development towards smarter, more efficient and safer critical systems. Examples would be accurate pedal position monitoring and steering-by -wire using hall effect sensors with redundancy levels and self-diagnostic features. Special ranges of contactless position sensors with low power consumption and a wireless option suitable for harsh environment with shock and vibration resistance are used for engine transmission control. In Electric Vehicles, battery pack condition sensing is required to check the state of the battery, highly accurate pressure sensing is used to detect overload or overcharge, and CO2 sensing to detect for emitted gases due to cells aging or over stress. These battery checks are essential for the safe operation of the vehicle and prolong the battery life. Private charging stations require high electric energy and non-symmetric loading may temporarily overload phases.

AC current transforming sensors are used at the charging stations to evaluate the overall power consumption and provide controls to the charging electronics to keep charging within the allowed limits.  When considering driver comfort and automation, use of sensors is critical to optimize dynamic vehicle controls such as sensors to support driver assistance systems (ADAS) like automotive braking systems (ABS) and cruise control. For energy management, humidity, temperature and pressure sensing innovations control the vehicle cabins climate control and windshield defogging optimizing energy consumption. 

And, sensing development is also aiding construction vehicles and agricultural machinery control. Using MEMs technology, Inertial Measurement Units (IMU) can provide motion, position, & navigational sensing in a housed package with over six degrees of freedom. These new harsh environment packaged sensors can be used to provide real-time vehicle position, such as vehicle angular rate, acceleration, and attitude data.

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UAVs and Drone’s flying capabilities have improved significantly, they are easier to control, more stable and lighter weight. Sensors need to provide accurate measurements even though there is substantial vibration from the built-in motor and temperature fluctuations to handle.

High performance barometric pressure sensors provide accurate height and GPS tracking, and MEMs motion sensors like IMU and gyroscopes help aid the stabilization of the device even during high winds. UGVs employ MEM technology too, accelerators, inclinometers, gyro and IMUs are all used in the navigation, and proximity sensors for detection of metal targets. The robotics systems on the UGV will also need position and motion sensors to measure robot arm rotation and force torque sensors for robot hand grip.  

Wearables for soldiers is certainly an emerging trend with wearable wrist devices logging heart rate, body temperature, respiratory, and sleep cycles for soldier health and stress monitoring. And wearable GPS watch for location, direction, and speed is used for tactical co-ordination between the ground troops and the command centers. Smart clothing can employ sensors for wound detection and environmental sensors can be embedded in clothing to detect radiation, viruses, chemicals or humidity measurements. Within the soldier’s helmet, gyros are used to stabilize the imagery for head up displays; impact/shock sensors can also be embedded into the helmets to detect head injury pressure points, to improve future design of the helmet and understand the impacts to the solider head.

Pressure, MEMs, position, force, proximity, temperature and gas sensors are just some of the sensors mentioned for these applications, but more and more sensing applications are emerging, and the trends are for greater wireless connectivity to join up these sensor networks.

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