What makes Sensata Wireless Solutions Ideal for Manufacturing Lines?

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The development of new technologies contributed to many industrial revolutions. One that opened up vast opportunities for controlling machines and improving the factory plants is Industry 4.0. Among others, the wireless solutions had the impact that contributed to the revolution.

Wireless technology is one of the most widely used in manufacturing today, with benefits felt throughout the value chain. In smart manufacturing, sensing technology allows for continuous asset monitoring where wireless networks eliminate the installation and maintenance costs associated with wired solutions.

The Role of Wireless Solutions in Industry 4.0

In the fourth revolution, wireless systems facilitate data transfer from one location to another. They allow for greater data transmission. Wireless networks have always fueled smart production, starting with 4G and subsequently shifting to 5G. The 5G is the next generation of mobile communication technology that offers higher speed, advanced analytics and big data. 

Wireless devices connect equipment that needs to move around freely and allow for machine-to-machine connectivity. The wireless solutions are in almost all sectors of the factory floor. It covers development to production, as well as storage and distribution. It also helps solve the issues that come in any of these processes. Thanks to that, the response for instructions in robotics and automation is under control. It is especially important because soon, many factories will move from Industry 4.0 to Industry 5.0, where the cooperation between robots and humans will play the biggest role.

The key factors to global mobile traffic growth are wireless devices’ ever-changing mix and growth. According to Cisco research, by 2023, 8.7 billion portable or personal mobile-ready gadgets will be in use. Between 2018 and 2023, North America and Western Europe will have the highest growth in mobile devices and connections, with CAGRs of 16% and 11%.

Sensata Wireless Systems

With the growth of new technologies, sensing solutions are also growing, especially for those that allow for communication in a secure wireless manner. Sensata helps your business achieve its digital transformation goals by providing wireless solutions that securely transmit and receive mission-critical data from various sources and integrate seamlessly into your existing automation system.

Sensata’s wireless system devices simplify the addition of IoT connectivity to industrial equipment, for increased productivity and safety. They help eliminate installation and maintenance costs associated with wired systems for continuous asset monitoring.


From basic cable replacement systems to full IIoT solutions, Sensata wireless solutions offer many applications. Sensata’s wireless system devices, including wireless pressure and temperature sensors, receivers, transmitters, and gateways, are versatile and configurable, making the installation of IoT connectivity for industrial equipment simple and cost-effective. The wireless sensors eliminate the need for costly or time-consuming cable runs while providing precision, reliability, and durability.

Benefits of Wireless Connectivity 

With a rising number of manufacturing companies seeing the benefits of wireless technology, its adoption is only anticipated to grow. As per Sensata, there are five main wireless connectivity benefits that smart factories gain:

  1. Optimise performance.
  2. Increase productivity
  3. Reduce costs
  4. Increase plant’s reliability
  5. Increase machine assets

The concept of smart manufacturing is based on increased labour productivity and reliability, reduced cost, high machine assets and optimised performance. Source: Sensata

Optimised performance

Now with the industrial revolutions growing, the capabilities of factories are changing. Optimising the manufacturing floor can help produce faster and better products. Wireless sensors and systems integrated into automation equipment enable precise control. The system delivers data wherever the process changes. The speedy response aids in the operation and performance of the company.

Increased productivity

Factories with only a few automation systems are working way slower than smart factories. The manufacturing equipment that is based on wireless technology can improve the factory plant by working longer and more efficiently. Thanks to automation, this can also remove route-based maintenance and manual tasks.

Reduced costs

Wireless solutions help automation systems run as efficiently as possible, generating little waste heat, utilising the least amount of power, and maximising all plant resources. Because wireless solutions function on low voltage, they can also eliminate the requirement for electricians. Manufacturing becomes more cost-effective and productive as a result of all of this.

Increase plant’s reliability

Wireless communication can replace material and labour costs and remove long and intricate wiring runs. Plants become more reliable as a result of the combination of these factors. The reliability works on an increase in production and finally benefits the company.

Increased machine assets

The profitability grows when machines are in use. Factories with little availability and low production times cannot achieve high performance. To avoid downtimes, it is important to invest in wireless connectivity. 

The new industrial revolution is driven by wireless connectivity

In the era of innovations transforming outdated plants into digital factories should start as soon as possible. With the growth of industry 4.0 and the advent of the IoT, industries are going through some changes, mostly digitalisation. Businesses that stay behind with production and do not keep up with the changes will not succeed. The wireless connection is driving the industrial revolution with components, such as sensors, machines and other devices waiting to be connected. 

Examples can be new Human Machine Interfaces (HMIs) that use augmented and virtual reality. They need to meet the same requirements for delivering high-resolution visuals and quickly responding to the user’s gestures. Besides that, mobile robots require ultra-reliable, low-latency connectivity and a high-fidelity data line. Also, sensors need to connect with other sensors or machines and be able to work consistently in crowded environments. All of these devices need wireless capabilities. 

Source: Sensata

Wireless Pressure Sensor, Sensata Cynergy3

The IWPTLU Wireless Pressure Transducer is a low-cost alternative to a normally wired pressure transducer. It allows low-cost installation in inaccessible and costly installation areas. An IWR-1 or IWR-5 receiver can be used with the IWPT sensor. Depending on the wireless receiver utilised, a line-of-sight range of up to 1640 feet is achievable. 

Wireless to USB Gateway, Sensata Cynergy3

The IWR-USB Gateway connects wireless sensors to any computer that has a USB port. All of the sensors in the wireless network can be monitored and logged using a regular PC using a free software programme. The time-stamped data acquired by the IWR-USB is saved in a standard.csv file for easy processing by programmes like Microsoft® Excel®.

Channel Wireless Receiver, Sensata Cynergy3

The IWR-1 is a single-channel receiver that works in conjunction with the IWPT and IWTT wireless pressure and temperature transmitters to create a cost-effective alternative to standard wired transducers. This provides a low-cost alternative to inaccessible or costly installation situations. Features: pairs with the IWPT/U & IWTT/U wireless pressure & temperature transducers. It uses user-selectable 1-5V or 4-20 mA receiver output, with DIN rail or wall mounting kits available.

Wireless Transmitter 2.4GHz 200mV, Sensata Cynergy3

The IWCTT Wireless Transmitter is a low-cost alternative to traditional wiring that provides low-cost installation in inaccessible and costly installation locations. Operates with any Split Core current transformer with a mV AC output, usually 333mV. It can be readily connected to any of the IWR receivers, making it a “plug and play” solution for your present measurement application.

IoT Gateway, Sensata Cynergy3

Virtually any sensor may be monitored from anywhere with a cellular connection thanks to the IoT Gateway. Features: available real-time monitoring of remote assets via the internet, includes 2G/3G/4G modem and digital communications ports for data acquisition, input types include Analog/digital I/O, IWT wireless sensors, and I²C /SPi sensors, can be battery or 12-24 V dc powered.

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