Sensing and I/O

Sensing and I/O For Automation Applications

When automating a process, you often need to see items moving through your line. However, because machines lack eyes, this is accomplished by using sensors that relay the information they gather back to the controller through I/O, or inputs and outputs. These sensors are used to check for the presence or absence of products or materials as well as position, size, color, or other characteristics.

There are a number of types of sensors used in automation. The first is photoelectric which uses light to detect an object. The next is inductive sensing which uses an inductive field to detect primarily metal-based products. Finally, ultrasonic sensors use sound waves to “see” products or materials. The form factors of these sensors can vary greatly in size and shape to fit most any process.

When it comes to industrial automation, input/output devices and sensors are critical for real-time data gathering from industrial and automation equipment. Which allows for increased control over your industrial processes as a whole. If your operation needs data acquisition, monitoring, or actuation, you’ve come to the right place. Cross Company can provide your operation with the sensing equipment and I/O devices you need to succeed.

Why Use Sensors or Input/Output Devices?

Sensors send output changes of state information back to the machine through I/O. While all I/O can connect directly into your main panel, many are now moving to remote I/O as it allows you to minimize the amount of wiring you require around the machine itself. Remote I/O units can be located on the machine itself, or they may be in smaller remote enclosures that are then connected to the main controller via a variety of either ethernet or serial protocols.

You will find sensing and I/O in almost any discrete manufacturing setting as well as in warehousing and logistics. They are used in manufacturing lines, conveyor systems, small stand-alone machines, and quality control applications. Both help to improve efficiency by quickly relaying information back to the controllers and eliminating the need for human eyes on the line at all times. Sensing can also help you to improve the quality of your product by spotting flawed items before they reach customers. Additionally, they reduce the risk of human error and recalls.
Because there are so many options available for sensing and I/O, we encourage you to speak with one of our experts. Our team has years of experience helping customers choose the right sensor for their applications.

Remote panel connectivity

Improved manufacturing lines

Optimized conveyor systems

Increased quality control

Greater operational efficiency

Reduce risk of error or recall

Benefits of Sensing and I/O Devices in Industrial Automation

Integrating sensing and I/O devices into industrial automation can provide many benefits to manufacturing facilities and other industrial operations. Some of these benefits include

Data-Driven Decisions

With sensing and I/O devices, real-time data is available on machine performance and process health. They also allow automation systems to detect anomalies, predict failures, trigger appropriate actions, and provide the data necessary for predictive maintenance

Greater Efficiency

Precise and reliable data from sensing devices allows for precise control over your industrial process. In turn, this leads to increased speed, productivity, and efficiency. Automated feedback based on data from sensors also reduces both waste and downtime in processes

Cost Savings

Using sensing and I/O devices (combined with connectivity and networking solutions) enable remote monitoring and control of industrial processes. This centralized management allows for control over temperature, pressure, flow, and more, resulting in significant cost savings

Applications of Sensing and I/O Devices

There are applications for sensing and I/O devices across a wide range of industries. As the industrial landscape changes, manufacturing operations have to change with it. Adapting automation equipment like sensors or I/O (or even replacing legacy automation equipment) can be the competitive advantage your operation needs over your competitors. Other applications include:

Process control – Sensing and I/O devices are found extensively in manufacturing plants for control of production processes, increased quality assurance, and precise monitoring.

Building automation – In automation systems for facilities, sensing and I/O devices are used to monitor temperatures, lighting, access control, and security. They are also able to provide real-time data on environmental conditions of the facility itself, which enables an energy-efficient operation

Energy management – Sensing and I/O devices are necessary components of automated energy management systems. They can keep track of power consumption, renewable energy generation, and ensure energy is being used optimally.

Environmental monitoring – Sensing devices are used in environmental monitoring applications to measure parameters such as air quality, noise levels, humidity, and radiation. This data helps in ensuring compliance with environmental regulations and maintaining a safe and healthy environment.

Cross Sensing and I/O Providers

Why Cross Sensing and I/O?

As the manufacturing world becomes increasingly competitive, automation is no longer a luxury. It can even mean the difference between your operation and a close competitor’s. Robotics, motion control devices, and other automation equipment have become integral parts of many manufacturing processes. When integrated properly, industrial automation can increase throughput, productivity, and worker safety.

Whether you need to implement automation systems for the first time or you’re looking to upgrade an existing system, Cross can work with you to develop custom solutions. We have the industry partnerships, technical industrial expertise, and world-class customer service necessary to provide you with the precision motion control products and accessories your operation needs.

Contact a member of Cross Automation today to start the process and get the automation products, components, or accessories you’re looking for. And see for yourself why so many operations choose Cross as their single-source solution for industrial automation.