How Does a Voltage Sensor Work? Definition and Common Uses

Voltage sensors are wireless tools that can be attached to any number of assets, machinery or equipment. They provide 24/7 monitoring, constantly watching for voltage data that could indicate a problem. Low voltage may signal a potential issue, while other assets may be in danger when voltage is too high. When thresholds are exceeded, alerts are immediately sent to a centralized computer system.

Voltage sensors detect magnetic fields, electromagnetic fields, and measure contact voltage. Maintenance teams can use this information to have a better understanding of their equipment and assets.

What is a Voltage Sensor?

Voltage sensors measure and communicate electric currents in equipment, devices, batteries or other sensors. This can help a maintenance team identify areas that need immediate attention or alert the team of a rising problem.

How Does a Voltage Sensor Work?

Voltage sensors can detect several things, including:

Magnetic Fields

These sensors measure magnetic flux as well as the direction and strength of a particular magnetic field between two components. They can be used in navigation equipment, industrial applications or scientific measurement. If a sensor detects that a magnetic field is weak, it can send an alert to your computerized maintenance management system (CMMS).

Electromagnetic Fields

Electromagnetic field sensors, which can detect accelerating charged particles, monitor the strength of these waves in critical assets. Also used in navigation, industrial and scientific applications, these sensors can alert a company’s CMMS when electromagnetic fields grow weak.

Contact Voltage

Sensors designed to measure contact voltage can be used in a wide variety of applications and industries. One common application is battery monitoring. For instance, a battery is installed in a piece of equipment and slips out of place several months later. This sensor will detect that the contact voltage has dropped and send an alert to your CMMS. A maintenance technician can then follow up and re-establish contact.

The Three Main Types of Voltage Sensors

Voltage sensors are wireless tools designed to detect changes in different kinds of voltage across many types of assets. When a discrepancy is detected, an alert can be sent to a facility’s CMMS and predictive maintenance can be performed.

AC Sensors

These sensors measure AC voltage. Typical applications include power demand control, power failure detection, and load sensing. Safety switching and motor overload control can also be managed with AC sensors.

DC Sensors

If you need to monitor DC voltage, these sensors will do the job. Energy management and building control systems can benefit from DC voltage sensors. Other common applications include fault detection, data acquisition, and temperature control.

Specialized Sensors

As technology continues to advance, other types of voltage sensors will be developed for specialized usage. For example, high-voltage applications may require special sensors, and many use fiber optic components to monitor voltage levels.

Popular Uses for Voltage Sensors

Voltage detectors are affordable tools that facilities can use to provide around-the-clock monitoring of critical assets. Properly operating power sources are key to keeping your equipment up and running reliably. Here are some popular uses for voltage sensors.

Power Demand Monitor

Sensors can be used to record which assets and equipment are consuming the most power. Decisions can then be made later regarding energy efficiency or conservation.

Power Failure Monitoring

A power failure can obviously have devastating effects within a facility. Voltage sensors can alert management to a drop in voltage, which may signal an impending power failure.

Load Sensing

These sensors are frequently used in hydraulic systems to detect whether a particular pump is functioning properly.

Fault Detection

They can be used to pinpoint a particular fault in a piece of equipment or within an overall system.

Temperature Control

Temperature sensors, which are designed to monitor whether an asset or area is within an acceptable temperature range, may malfunction. If this occurs, they often emit excess voltage, which can be picked up by a voltage sensor.

Safety Switching

Faulty wires can increase the risk of electric shock to your employees. Voltage sensors can be connected to a safety switching system, which will automatically shut down or re-route the voltage. An alert can also be sent so that the faulty wires can be repaired.

Motor Overload Control

Voltage sensors can monitor and detect the current drawn from an overloaded motor. When a threshold is reached, the motor can shut down before expensive damage occurs.

Energy Management Controls

By providing voltage usage data, these sensors can help a facility optimize energy generation, transmission, and usage within a business.

Building Control Systems

Building controls such as security and HVAC systems must be operating at all times to allow a business to function effectively. These sensors can help ensure these systems are in good working order.

Fault Detection

When voltage drops too low or approaches dangerously high levels, this may signal potential equipment malfunctions. Preventive maintenance tasks can then be scheduled before major issues commence.

Data Acquisition

They  can make a significant contribution to building historic maintenance data in your CMMS. By collecting information on asset performance as well as maintenance frequency, you can make better long-term decisions.

Conclusion

Voltage sensors are inexpensive tools that can make a big difference in improving your predictive maintenance program. When used in combination with a reliable CMMS solution,  sensors can provide a wealth of data for your organization. This information can then help your maintenance management team make strategic decisions about repair, investments, and process changes.

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