Issue link: https://resources.mouser.com/i/1536939
Introduction When a critical 400 kW air compressor in a busy manufacturing plant develops an early- stage bearing fault, traditional monitoring approaches might completely miss it—until catastrophic failure brings production to a standstill. But what if that same fault could be detected weeks ahead through subtle vibration signatures processed by edge AI algorithms that automatically trigger maintenance alerts? This is the power of intelligent sensor fusion in modern industrial automation. Sensors have emerged as the driving force behind transforming traditional factories into intelligent, adaptive, and self-optimizing facilities. They serve as the smart factory's eyes, ears, and hands—quietly collecting vast amounts of real-time data that flows through networks of connected systems, which feed into analytics and AI algorithms that enable manufacturers to make quicker decisions and respond to changes with unprecedented agility. Today's manufacturers encounter a convergence of challenges: unplanned downtime accounts for 24% of total production costs, global competition intensifies daily, labor shortages strain operations, and the growing demands of the robotics industry require new levels of precision and flexibility. To succeed, manufacturers must go beyond traditional linear production models and embrace smart factory technologies where modern robots work as flexible, collaborative partners alongside human teams, learning from their environment and adjusting their actions in real-time. This ebook explores how advanced sensor fusion creates a new reality. You'll discover how modern MEMS accelerometers match the performance of traditional piezoelectric sensors while enabling wireless, battery-powered condition monitoring systems. Learn how edge AI processing can reduce power consumption by 80% while providing real- time insights that prevent costly failures. Explore how inertial measurement units enable robots to navigate complex environments without external references, and how breakthrough multi-turn position sensors eliminate the need for re-homing automation equipment—addressing one of the most persistent challenges in industrial automation. Each chapter integrates fundamental principles with real-world applications, showcasing innovative solutions from Analog Devices, Inc. (ADI), a global leader in high- performance sensing technologies. From vibration analysis that identifies bearing faults at their earliest stages, to edge processing platforms that extend battery life to seven years, to multi-turn position sensors that preserve accuracy during power outages— you'll discover how this blend of sensors, robotics, AI, and machine learning establishes the foundation of truly autonomous manufacturing systems. Whether you are designing condition monitoring systems, implementing autonomous robotics, or developing next-generation industrial automation, this ebook offers the technical insights and proven solutions—easily accessible through Mouser Electronics—that you need to create agile, adaptive, and self-optimizing production facilities that keep up with the demands of the 21st century. The smart factory revolution isn't coming—it's here. 3 Engineering Reliable Industrial Automation With Sensor Fusion