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Industrial Sensors in Automation Systems: PLC Integration, IO-Link, Safety, Networks and Smart Diagnostics
Paperback
Series: Industrial Sensors and Automation, Book 4
Publisher: Independently Published
Published: Jul 14 2026
Pages: 194
Weight: 0.53
Height: 0.49 Width: 6.00 Depth: 9.00
Language: English
Modern industrial sensors do far more than switch a PLC input. They exchange process data, report diagnostic information, store parameters, support automatic device replacement, communicate through industrial networks, and contribute to machine safety, maintenance, and production quality.
Industrial Sensors in Automation Systems explains how sensors become part of a complete automation architecture-from the field device and remote I/O station to the PLC, IO-Link master, industrial network, HMI, SCADA system, safety controller, and maintenance platform.
Written for maintenance technicians, automation engineers, electricians, machine builders, commissioning specialists, and students, this book focuses on the practical integration of sensors into real industrial systems.
Inside, you will learn how to:
- Integrate digital, analog, and smart sensors with PLC systems
- Understand PLC scan cycles, input filtering, timing, and signal quality
- Configure and diagnose IO-Link devices and masters
- Work with PROFINET, EtherNet/IP, remote I/O, and industrial communication networks
- Use device parameters, identification data, and automatic replacement functions
- Preserve diagnostics from the field device to the HMI and SCADA system
- Integrate encoders, RFID systems, vision sensors, and condition-monitoring devices
- Understand the role of safety sensors and safety-related signal processing
- Diagnose communication faults, timing errors, unstable values, and lost device data
- Improve commissioning, validation, documentation, and maintenance procedures
- Design systems that are easier to troubleshoot, expand, and support
The book shows why a sensor may operate correctly while the machine still behaves incorrectly. A problem can be caused by delayed signals, incorrect addressing, network configuration, poor parameter management, weak diagnostics, PLC logic, or lost context between automation layers.
Practical examples, comparison tables, diagnostic checklists, network concepts, commissioning methods, and real factory fault cases connect theory with everyday industrial work.
The central principle is simple: a sensor signal has value only when the complete system can acquire it, interpret it, trust it, diagnose it, and use it safely.
Whether you are designing a new machine, commissioning an automation system, troubleshooting production failures, or modernizing an existing installation, Industrial Sensors in Automation Systems provides a clear and practical guide to connecting field-level sensing with modern PLC control, industrial networks, safety systems, and smart diagnostics.
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