Sudden voltage changes can indicate serious issues with production line machinery. Voltage sensors track, measure and report these changes, allowing teams to take immediate action and resolve potential problems.
Let’s break down the basics of voltage sensors including what they do, how they work and what types are commonly used. We’ll also explore the practical applications of voltage sensors, discuss their practical benefits and offer advice on selecting the right voltage sensor for industrial use cases.
What is an industrial voltage sensor?
An industrial voltage sensor measures both the input and output voltage.
Voltage is the potential energy difference between two points in a circuit. The higher this potential difference, the faster the flow of electricity. Voltage sensors measure and report these potential energy differences.
These differences may be reported as analog or digital signals. For example, a digital sensor might include an LED display panel that reports voltage change as a number. An analog sensor, meanwhile, might use a moving needle to represent voltage values.
Voltage sensors differ from other types, such as pressure or current sensors. While these tools measure flow, voltage sensors measure difference.
Industrial voltage sensors help companies detect power quality or quantity issues, ensure continued operations and improve worker safety.
How industrial voltage sensors work
Voltage sensors work by measuring the potential energy at two points in a circuit or device and then reporting these values. Electricity flows from lower to higher energy points, meaning that current naturally moves from low voltage to high voltage.
Industrial voltage sensors are designed to detect voltage at two (or more) points. This detection may be accomplished using resistance, capacitance, optical measurements or the application of specific electric principles such as the Hall Effect.
Voltage sensors translate the potential energy of each point into volts (V), which are then reported to monitoring systems or controllers. These sensors are typically integrated into systems using programmable logic controllers (PLCs), data loggers or machine health monitoring systems.
Types of industrial voltage sensors
There are multiple types of voltage sensors, such as:
- AC Voltage Sensors — AC voltage sensors are used to monitor alternating current motors, transformers and power supply systems.
- DC Voltage Sensors — DC voltage sensors help monitor batteries, control panels and other DC-driven equipment.
- Optical Voltage Sensors — These sensors use light-based voltage measurement, which makes them ideal for high-voltage, non-contact applications.
- Hall Effect Voltage Sensors — The Hall Effect refers to the deflection of charges toward one side of an electric conductor when it is exposed to a magnetic field. These sensors are often used in power supplies, power meters or electrical panels.
- Voltage Divider Sensors — Voltage divider sensors use a resistive approach to detect voltage. As a result, they are often used for low-cost or educational applications.
All of these sensors can take various forms. They may be proximity sensors, wireless sensors or hardwired sensors. They may connect to power supplies, power transducers, current transducers or any other electrical systems.
Applications of voltage sensors in manufacturing environments
Voltage sensors can be used in any manufacturing environment that involves electricity. They are most commonly found in production line equipment and heavy machinery. These sensors provide real-time information about dips or surges in voltage that may indicate larger issues.
Consider a piece of production line equipment that experiences a sudden voltage increase. This could indicate a short circuit or other failure that puts the rest of the system at risk. Sensor notifications allow teams to take machines offline, pinpoint the problem and resolve the issue.
These sensors can also be used to track voltage changes over time. For example, if a piece of heavy machinery shows a slow but steady decline in overall voltage, this may indicate the need for repair or maintenance.
Common voltage sensor applications include:
- Energy management
- Efficiency monitoring
- Motor control
- Electrical system protection
Voltage sensors perform best when integrated with electrical preventive maintenance platforms. This allows teams to detect electrical faults early and act before serious damage occurs.
Benefits of industrial voltage sensors
The biggest benefit of voltage sensors is the timely access to information. Faster insights enable maintenance teams to take preventative action — rather than reacting only after equipment fails.
Other key benefits include:
- Reduced downtime — Early warnings can prevent equipment shutdowns or malfunctions.
- Increased energy efficiency — Voltage sensors monitor excessive drops or increases to help improve system performance.
- Enhanced workplace safety — Sensors mitigate the risk of electrical faults by providing data to help teams maintain proper voltage levels.
- Improved predictive processes — Data collected over time helps forecast potential issues and create data-driven maintenance schedules.
Selecting the right voltage sensor for industrial use
Both the application and the device inform the choice of the voltage sensor. In practice, companies should consider five factors in their sensor selection process:
1. Voltage range compatibility
Sensors must be matched with the expected system voltage. For example, if the system voltage is two or three times higher than the sensor capacity, the sensor is rendered useless.
2. AC vs. DC
AC sensors do not work in DC environments, and vice versa. Consider a temperature sensor. If you select a DC tool for an AC application, the sensor will not detect any voltage change.
3. Operating environment
Environmental conditions such as temperature, moisture and the presence of dust or dirt inform sensor choice. For example, wireless sensors may be the best choice for environments that are difficult for staff to access.
4. Accuracy and response time
Sensors may report voltage drops immediately or on a set schedule. Voltage sensors may either process and convert data instantly or require some time to do so. The more critical your system or device, the shorter response time required.
5. Integration capabilities
Finally, teams need to consider the ease of sensor integration with existing control systems, current transformers or PLCs. Complex integration can lead to missed data, which may put operations at risk.
Role of voltage sensors in maintenance programs
Voltage sensors play a key role in both preventative and predictive maintenance sensor programs.
For example, remote condition monitoring enables early detection of voltage instability issues before they escalate. When integrated with machine health monitoring platforms and CMMS tools, you can contextualize sensor data. In combination, these approaches form the foundation for maintenance programs that use voltage fluctuations as a key indicator for predictive repairs and replacements.
ATS can help your team leverage this data to improve overall uptime. With our eFactoryPro CMMS, MRO asset management and Reliability 360® Machine Health Monitoring, we have the tools and expertise to detect issues early and address problems before they occur.
Partner with ATS for smart industrial sensor solutions
With ATS, you get the triple benefit of industry experience, end-to-end support and custom maintenance strategies.
Our teams have expertise in sensor integration, predictive maintenance and electrical system optimization, which helps ensure both steady operations and streamlined reporting. In addition, we offer thermographic testing services and provide a robust machine health monitoring solution to ensure your voltage data is effectively logged and leveraged.
We also recognize that no two electrical systems are exactly the same. Our custom industrial maintenance strategies are tailored to your needs and operations, helping reduce downtime, minimize repair costs and improve safety.
Keep your electrical operations up and running with complete voltage sensor support. Contact ATS today for a consultation or on-site assessment.
