INDUSTRIAL SENSORS IN AUTOMATION SYSTEMS
PLC Integration, IO-Link, Safety, Networks and Smart Diagnostics
Series: Industrial Sensors And Automation Series
Modern industrial sensors do far more than switch a PLC input. They transmit process values, diagnostic data, identification information, and device parameters. They also support automatic replacement, condition monitoring, machine safety, quality control, and integration with industrial networks.
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. The focus is on practical integration, signal reliability, diagnostics, commissioning, and real factory troubleshooting.
WHO THIS BOOK IS FOR
This book is written for:
• Automation and control engineers
• Industrial electricians and maintenance technicians
• PLC programmers and commissioning specialists
• Machine builders and system integrators
• Electrical panel designers
• Technical students and trainees
• Professionals modernizing industrial equipment
WHAT YOU WILL LEARN
Inside this book, 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 remote I/O and industrial communication networks
• Use device parameters, identification data, and replacement functions
• Preserve diagnostic information from the sensor to the HMI and SCADA system
• Integrate encoders, RFID devices, vision sensors, and condition-monitoring equipment
• Understand safety sensors and safety-related signal processing
• Diagnose communication faults, timing errors, and unstable values
• Identify incorrect addressing and parameter-management problems
• Improve commissioning, validation, documentation, and maintenance
• Design systems that are easier to troubleshoot, expand, and support
TECHNICAL AREAS COVERED
The book examines the main devices, networks, signals, and integration concepts used in modern sensor systems, including:
• Digital and analog industrial sensors
• Smart sensors and diagnostic data
• PLC input processing and scan-cycle behavior
• Input filtering, debounce timing, and signal validation
• IO-Link sensors, masters, parameters, and process data
• Remote I/O stations and distributed automation
• PROFINET and EtherNet/IP integration
• Industrial network addressing and device configuration
• HMI and SCADA diagnostic presentation
• Encoders and position-feedback systems
• RFID identification and tracking
• Vision sensors and inspection systems
• Condition-monitoring sensors
• Safety switches, light curtains, and safety sensors
• Automatic device replacement and parameter recovery
• Commissioning, documentation, and fault isolation
WHY THIS BOOK MATTERS
A sensor may operate correctly while the machine still behaves incorrectly. The real problem may be delayed signal processing, incorrect addressing, weak diagnostics, lost parameters, network configuration, PLC logic, or missing context between automation layers.
This book follows the complete signal path and explains how data is acquired, transmitted, interpreted, validated, displayed, and used by the control system. Practical examples and realistic fault cases show how small integration weaknesses can become repeated production problems.
Industrial Sensors in Automation Systems is a practical guide to connecting field-level sensing with PLC control, industrial networks, safety systems, and smart diagnostics.
A sensor signal has value only when the complete system can acquire it, trust it, diagnose it, and use it correctly.
