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Smart Sensors

HBK´s Smart Sensors feature integrated signal conditioning capabilities and industry-proven bidirectional communication interfaces. This enables digital pioneers to create new innovative solutions for machine digitization, manufacturing processes and monitoring applications.

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From Analog to Digital to Smart: A Sensor Evolution

The progression of sensor technology has seen a transition from analog to digital to smart sensors, driving significant advancements in accuracy, intelligence, and connectivity. In general sensors measure a physical quantity such as strain, force or acceleration and convert it into an electrical signal. Sensors with analog circuits generate a continuius output signal but they have limited signal conditioning capabilities. Digital sensors convert the measured physical values into discrete binary values enabling more sophisticated filtering and scaling functionalities. Smart Sensors take it a step further, incorporating microprocessors with high-performance internal signal conditioning capabilities and bidirectional communication interfaces. This equips a smart sensor with the intelligence to analyze, interpret, and perform domain-specific calculations on the measured physical values which enables real-time decision-making taking place within the sensor.

Smart Sensors are called ”smart” because of their ability to provide the necessary results that the underlying machine, process or system requires in order to function, in many cases eliminating the need to process the raw data in the plc. This shift in concept enables decen-tralization and allows innovative new system architectures for devices, machines, manufacturing- and testing processes and monitoring solutions.

for K-C9C VA2 plus C9C AV IO-Link mV-V interfaces picto - Electronic sample board isolated

Accuracy, Intelligence and Connectivity

Smart Sensors enhance precision by leveraging additional measurement data such as temperature or acceleration readings from secondary sensing elements within the sensor. Due to the integrated electronics, these sensors can perform calculations to compensate the impact of temperature and vibration on the actual measurement signal. HBK´s expertise spans a wide range of sensor domains, from strain, force and torque to sound and vibration. Utilizing this domain-specific knowledge, we implemented signal-processing algorithms covering the time and frequency domain which allow smart sensors to perform fit-to-purpose calculations and self-monitoring tasks referred to as ‘smart functions’ and ‘condition indicators’.

In practical terms, this entails the automatic tracking of datasheet information, including nominal load thresholds. When specific limit thresholds are exceeded, alerts are promptly dispatched to the connected control system. Control engineers can also request access to current sensor temperature as well as historical data such as runtime and excitation limits, providing them with valuable insights into the sensor's performance and status.
 

Commercial and Efficiency Benefits

Aside from technical advantages, our customers can benefit commercially and operationally from smart sensors. Integrated electronics eliminate the need for external amplifiers and significantly reduce cabling costs through digital signal transmission – double-shielded cables with twisted pair wires are no longer necessary. Pre-processing measurement readings within the sensor enhances the feasibility of decentralized solutions, also reducing data overload on the PLC (programmable logic controller).

Standardized communication protocols such as IO-Link help to significantly reduce commissioning time compared to traditional measurement chain setups, due to the open standard of the IO-Link protocol and its data and sensor profile management, allowing for easy sensor switching and parametrization. Overall, smart sensors allow for the realization of new machine and monitoring concepts, which truly enable Industry 4.0 solutions such as connected smart devices and advanced monitoring solutions.

Discover our smart sensor features and benefits through our interactive graphic.

Illustration of an infographic showing smart functions and features of smart sensors in isometric perspective

Benefits of using HBK Smart Sensors

cost reduction picto

  • Cost reduction due to fewer component needed to build a sensing solution (no amplifier etc. needed
  • OTS components, building block system
  • No need for costly cables due to A/D conversion in sensor
Modular scalable picto

  • Enables new system architectures / process solutions.
  • Scalable, interoperability, easy switching/commissioning due to digital sensor ID and parameter files, etc...
  • IO-Link as open protocol, fieldbus independent 
  • CAN-MD can be integrated into existing CAN networks

HBK Smart Sensor Products

Our smart sensor range includes strain-gauge-based sensors, piezoelectric crystals, and MEMS integrated on the smart sensor PCBA (printed circuit board assembly).

Our communication interfaces support open standard bidirectional protocols such as IO-Link, CAN, and Industrial Ethernet. Find out more about our current smart sensor products below.

For enquiries about our smart sensor solutions and capabilities, please contact our dedicated sales team.

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