The benefits of digital intelligent sensors

The industry is digitizing. Gradually, more and more systems are being interconnected and intelligence is being added, leading to various benefits. The use of digital intelligent sensors for pH measurement, among other things, also offers companies added value. Martin Hoogedoorn, business unit manager Process and Dirk Vleminckx, application specialist at Elscolab explain.

"Digital sensors have been on the market for several years and are now well established. Digital communication replaces the analog variant. From the measurement transducer, the data are no longer transmitted analog, but digitally with Profinet, Ethernet IP, HART, Modbus and so on. But if you really want to make a difference, you use intelligent digital sensors," says Hoogedoorn. Elscolab has been a distributor of analysis, measurement, control and laboratory equipment for more than forty years.

More data

There are several digital sensors on the market for all kinds of applications, from measuring pH, gas analysis and refractive index to recording dissolved oxygen. "Intelligent sensors have more data than just the measured values: they collect information about the quality of the measurement, the history, the calibration and the degree of contamination and communicate this towards the control room," explains Vleminckx. He elaborates on the benefits.

Understanding status

"The main advantage of an intelligent digital sensor is that you know the status at any time. You can see how often and when and sometimes even by whom the sensor has been calibrated and whether the calibration went well. You also know how long the sensor has been in use, when it needs to be replaced, in what process conditions the sensor has been operating, and so on. For example, you can easily detect temperature spikes or other anomalies. An analog sensor is limited to transmitting measured values without considering history or conditions."

Self-learning algorithm

Hoogedoorn adds: "Digital intelligent sensors use a self-learning algorithm that takes process conditions into account. If maintenance is required, the sensor will make this known. In this way, predictive maintenance is possible. In addition, the sensor also indicates when it is time for calibration (ACT, Active Calibration Timer) or when the sensor needs to be replaced so you can replenish your stock in a timely manner."

Saving time and money

"Thanks to intelligence, you can save a lot of time and money," Vleminckx joins his colleague. He explains this further with an example. "A company with 100 pH measuring points in its production process decided to switch from analog to intelligent sensors. In practice, it turned out that the lifetime of the electrodes - the core of the intelligent sensors - could almost be doubled and thus the costs halved. The reason? Analog sensors are usually calibrated on-site at the production site. Intelligent sensors, on the other hand, can be easily exchanged and then calibrated offline in a workshop or laboratory under ideal conditions. This translates into a longer lifetime and more accurate measurement results. In addition, poor calibration leads to rejection, requiring analog electrodes to be replaced sooner. In short, with intelligent sensors you can save both time and costs."

Elscolab offers two platforms for easy reading of the intelligent sensors: ISM (Intelligent Sensor Mangement) and Memosens. Vleminckx: "With Memosens, the signal transmission is inductive, while ISM involves physical contact. Both platforms have now proven themselves in the market."