The process automation industry has begun a huge movement to switch from analog sensors to digital sensors. Also, digital communication can transport more information than analog. This makes it possible to generate more data about the process and devices on the field.
The article explains the role of digitization in liquid analysis and explores the advantages of updating to Memosens technology in the industry.
What is an analog sensor
An analytical sensor must have its “raw” signal converted into a readable measured value. For an analog sensor, we do this with a transmitter using calculation algorithms, which also consider sensor adjustments.
What is a digital sensor
In a digital sensor, the signals convert using a processor in the sensor head. The processor’s memory also stores the sensor data digitally. With all the data stored in the sensor, you can calibrate the sensor in the lab or in a computer and at the same time check the behavior in the last calibrations to predict the maintenance of the sensor.
Analog sensor vs digital sensor
Analog technology can cause a lot of complications. Corrosion and humidity can affect cables. Also, vibration can affect signal stability, making measurements inaccurate and inconsistent.
Here we list the possible problems you might face with analog sensors:
- Transmitter: Different compensation algorithms, temperature compensation, sensor user-handling, incorrect buffer management
- Cable: Galvanic isolation, static electricity build-up, bad grounding
- Sensor: Signal drop due to cable resistance, contact resistance, moisture, oxidation, or dirt
Switching from analog sensors to digital sensors
Digital sensors make your processes more cost-efficient and reliable. They last longer than analog, which saves you money in the long run. Plus, cleaning them in the lab gives you a chance to adjust your sensors for better accuracy, which also makes them last longer.
Not only that, but they generally need less maintenance, once again saving time and money. Analog sensors usually have a higher error margin, too, meaning more time troubleshooting. The measuring unit doesn’t change, but with better signal integrity from a digital sensor, accuracy improves.
Thanks to the inbuilt memory, each sensor has an identity. Knowing how it’s been running and in what environmental conditions will help you understand the process and prevent downtime.
Digital sensors transmit signals without interference, so multiple signals and sensor data (ID, diagnostics, etc.) can move on a single cable. You can also manage them with PC software.
What is Memosens?
Memosens is a “smart sensor” – it transforms analog readings into a digital signal, right in the sensor head. From a practical point of view, this means that your data won’t have cable issues, signal drops, static electricity, or the like. You’ll get 100% signal integrity.
It’s like listening to a song on a vinyl disc as opposed to an MP3 – no “noise” in your signal due to dust, scratches, wobbling, etc. For unusual readings, you can troubleshoot much faster, since you can rule out defective cable or electrical/magnetic interference (Memosens does not have metal parts).
The benefits of Memosens
The Memosens inductive sensor connector system sends both energy and data without contact between the sensors and analyzers. Galvanic isolation reduces interference and allows reliable measurements even with difficult setups.
As ground potentials no longer play a role, you won’t need solution grounding or equi-potential bonding. Memosens sensors also work in a multitude of environments, even underwater!
With pre-calibrated sensors, Memosens offers maximum availability and lower maintenance at the point of measurement.
MemoSuite gives you precise sensor calibration and documentation under reproducible conditions in the lab. Even non-specialist employees can replace sensors on site in a matter of seconds.
Less time and work in maintenance also reduces process downtimes. Along with the other benefits, Memosens pays for itself fairly quickly.
Extensive diagnostics improve your process management. Monitoring your sensor’s runtime, wear, remaining life, maximum temperature, calibration, and data significantly increases its reliability.
A Memosens device can make your applications more robust with its feedback on status, shelf life, possible errors, and more. In terms of process and upkeep costs, you should see a return on the investment, making it worth considering.
To know more about Memosens, you can get in touch with our engineers!