Deploying wireless condition monitoring sensors in automotive manufacturing

Automotive manufacturers face constant pressure to increase uptime, maintain production schedules and reduce maintenance costs. When assets such as conveyors, motors, utility systems, furnace fans, die-casting temperature control units and injection moulding heat exchangers fail unexpectedly, the disruption can quickly cascade across the production line. Wireless condition monitoring provides additional visibility into equipment health, helping maintenance teams identify developing issues before they create costly disruption.

Traditional maintenance programmes remain essential, but scheduled inspections may not reveal how equipment condition changes between visits. Wireless condition monitoring provides an additional source of information, helping engineers identify abnormal behaviour, investigate developing faults and plan maintenance before problems lead to more serious disruption.

IMI TWTG NEON non-Ex sensors offer a way to introduce additional monitoring points across suitable automotive manufacturing environments without necessarily installing new signal cabling or external power supplies. Using low-power LoRaWAN wireless connectivity, the sensors can transmit condition data from selected assets to a monitoring application, supporting more informed maintenance decisions.

Successful deployment depends on selecting the right equipment, matching each measurement to a defined maintenance objective, confirming the suitability of the installation environment and establishing a clear process for acting on the information.

The starting point for a condition-monitoring programme should be an assessment of asset criticality, rather than an attempt to instrument every machine.

In automotive manufacturing, the consequences of equipment failure can extend beyond the affected asset. A fault on a conveyor or transfer system, for example, may interrupt several downstream processes. A failure affecting a paint-shop utility, cooling circuit or compressed-air system may also constrain production across a wider area.

Engineering and maintenance teams should consider:

Potential candidates include conveyor motors and gearboxes, assembly-line drives, robotic-cell auxiliary equipment, ventilation fans, extraction systems, cooling-water pumps, hydraulic power units and selected plant utility systems.

The suitability of each asset depends on its operating conditions, failure modes and the measurement required. Existing programmable logic controllers (PLCs), supervisory control and data acquisition (SCADA) systems, and other instrumentation may already provide sufficient information for some applications. Wireless condition monitoring is particularly useful where additional data would address an identified gap.

A focused pilot involving a limited number of high-priority assets can help establish the technical and operational value of the approach before deployment is expanded.

Different measurements provide insight into different aspects of equipment performance. Sensor selection should therefore begin with the maintenance question that needs to be answered.

Rotating equipment is a natural starting point for condition monitoring in automotive manufacturing. Motors, conveyor drives, gearboxes, pumps and fans can develop mechanical faults that affect their efficiency before a breakdown occurs.

Changes in vibration can indicate potential issues such as:

The IMI TWTG NEON Vibration Sensor (Non-Ex) provides three-axis vibration measurements and spectral analysis, across a published frequency range of 0.5 Hz to 6.66 kHz, helping maintenance teams identify changes in asset behaviour that may warrant further investigation before unplanned downtime occurs.

Its onboard processing and configurable algorithms support the detection of changes in an asset's vibration behaviour, with event-driven and scheduled data transmission.

For example, a sensor installed on a conveyor drive motor or gearbox can monitor vibration behaviour and identify changes that may indicate developing mechanical issues, helping maintenance engineers determine when closer inspection is warranted.

Unlike conventional condition monitoring approaches that rely on establishing a baseline of normal operating behaviour, the IMI TWTG NEON Vibration Sensor (Non-Ex) sensor analyses vibration envelope spectra at the edge before transmitting the data. By examining harmonic frequencies and amplitudes, it can identify potential faults such as mechanical looseness, misalignment and bearing defects without first needing to learn a machine's normal operating baseline. This means it can also detect existing faults in machinery where issues may already be present, providing valuable insight from the outset.

Mounting position is important. The sensor must be installed in accordance with the manufacturer's instructions, with suitable mechanical coupling to the asset and a location that provides representative measurements. Operating speed, load and normal variations in production duty should also be considered when interpreting the results.

Temperature provides a complementary source of information about equipment condition. Abnormal thermal changes may be associated with bearing deterioration, inadequate lubrication, excessive loading, mechanical friction or cooling-system problems.

The IMI TWTG NEON Temperature Transmitter (Non-Ex) accepts compatible thermocouple or resistance temperature detector (RTD) inputs, allowing engineers to monitor selected measurement points on suitable equipment.

Potential automotive applications include:

The probe type, measurement range, attachment method and installation position must be appropriate for the application. The transmitter's specifications and the probe manufacturer's guidance should be checked before installation.

Pressure measurements can provide additional visibility of selected hydraulic, pneumatic and fluid-handling systems. In automotive facilities, these may include cooling-water circuits, hydraulic power units, vehicle fluid filling systems and other suitable utility or process applications.

The IMI TWTG NEON Pressure Sensor (Non-Ex) provides wireless pressure monitoring for applications where the selected pressure range, accuracy, process connection and installation arrangement meet the site's requirements.

For example, engineers may monitor a selected utility circuit to identify pressure readings that depart from an established operating range. Such changes can indicate a potential leak, restriction, equipment malfunction or change in operating conditions, but the measurement alone does not establish the cause.

Pressure monitoring should supplement, rather than replace, instruments and protective systems required for process control or safety.

Automotive production facilities contain a variety of operating environments, from general assembly areas to paint shops, machining operations and industrial utility rooms. A sensor that is suitable for one location may not be appropriate for another.

Before selecting an installation point, assess the actual conditions in which the device will operate.

Check ambient temperatures, local heat sources and temperature variations during production. Where the transmitter uses an external probe, verify that both the probe and transmitter are suitable for their respective installation conditions.

Machining areas may generate metal particles, dust or coolant mist. Other locations may be subject to routine cleaning, moisture or washdown. Assess the published ingress-protection rating, chemical exposure and mounting arrangement against the actual conditions. An IP rating alone does not establish suitability for every cleaning regime or industrial environment.

Consider vibration from neighbouring machinery, accidental impacts, moving equipment and the risk of damage during maintenance activities. Sensors and cables should be positioned to avoid interference with machine operation, guards, access routes and routine servicing.

Select locations that provide useful measurements while allowing safe inspection and servicing. Installation should follow site procedures, including any necessary permits, isolation arrangements and manufacturer instructions.

The NEON non-Ex variants are intended for environments where the relevant hazardous-area certification is not required. Some automotive processes, including certain paint-shop and solvent-handling operations, may involve potentially explosive atmospheres.

A site-specific assessment must establish whether the proposed location requires ATEX, IECEx or other hazardous-area approval. The non-Ex variant must not be installed in a location requiring certification that it does not hold. Where necessary, select an appropriately certified alternative.

NEON sensors communicate using LoRaWAN, a low-power wireless networking technology designed for long-range data transmission. Battery-powered operation can reduce the need for new signal cabling and external power supplies, making it easier to introduce additional monitoring points on suitable existing assets.

For automotive plants, this can be useful where equipment is distributed across large production halls, utility areas or locations where installing new cabling would be disruptive or expensive.

However, wireless connectivity must be assessed as part of the deployment, not assumed from the outset.

Before installation, confirm:

Building structures, machinery, metal enclosures and the location of gateways can affect radio performance. Coverage should therefore be verified under representative site conditions.

The data architecture also needs to be agreed. Depending on the application, monitoring information may be viewed through the IMI TWTG SolidRed platform or integrated with another compatible IoT or industrial data system. The appropriate communication configuration, decoder and integration method must be verified for the selected device and application.

Cybersecurity should be considered from the beginning. Define how devices and gateways are managed, who can access the monitoring data, and how the system connects to existing production and business networks. A separate monitoring architecture may be appropriate where site policies restrict connections to production networks.

A documented installation and commissioning process helps ensure that the monitoring system produces useful, reliable information.

Step 1: Confirm the asset and measurement point

Record the asset identifier, location, operating duty and reason for monitoring. Ensure the chosen position provides a representative measurement and is accessible for installation and future maintenance.

Step 2: Install according to manufacturer guidance

Follow the relevant product manual and mounting requirements. For vibration monitoring, pay particular attention to mounting position and mechanical coupling. For temperature and pressure measurements, verify the probe or sensor arrangement, connection type and permitted operating range.

Step 3: Configure the device and communications

Confirm the device configuration, LoRaWAN region, network registration and required data transmission settings. Ensure the selected monitoring application can receive and interpret the device's messages correctly.

Step 4: Verify measurements

Check that the readings are plausible for the equipment and its current operating state. Where possible, compare them with existing instruments, inspection results or established measurements. Investigate unexpected differences before relying on the data for routine maintenance decisions.

Step 5: Confirm the end-to-end data path

Verify that measurements reach the intended application and that asset identifiers, timestamps, visualisations and alerts operate as expected. Confirm that the data can be accessed by the personnel responsible for reviewing it.

Step 6: Document responsibilities

Agree who monitors the data, who receives alerts, how potential problems are investigated and where findings are recorded. Involve maintenance, reliability, production, automation and IT/OT teams as appropriate.

Wireless installation can simplify deployment, but it does not remove the need for safe access, approved work procedures or appropriate commissioning checks.

Collecting measurements is only the first part of a condition-monitoring programme. The operational benefit comes from interpreting the information and using it to support appropriate action.

Once the sensors are commissioned, establish baseline measurements under representative operating conditions. For automotive production equipment, this may require considering different production speeds, loads, product configurations and operating schedules.

Subsequent measurements should be reviewed against the baseline, taking account of normal variation and relevant changes in operating conditions.

A change in vibration or temperature, or a pressure reading outside an agreed range, may justify an inspection. It does not necessarily confirm that a component has failed or identify the underlying cause.

Engineers should consider the wider evidence, including:

Define alert thresholds and response procedures that reflect the application and the site's maintenance practices. Establish how alerts are prioritised, who investigates them and when an intervention is required.

Condition-monitoring data should complement existing control systems, safety interlocks, protective devices and maintenance procedures. It should not replace systems required for safe operation or the control of production processes.

A controlled pilot allows manufacturers to assess whether wireless monitoring provides useful information and can be sustained within existing maintenance processes.

Evaluation should consider both technical performance and operational outcomes.

Potential measures include:

Record the baseline and agree evaluation criteria before the pilot begins. Consider the number of assets monitored, the duration of the trial and any other changes to maintenance practices or production operations.

A short pilot may demonstrate that the sensors and communications work as intended, but it may not be long enough to establish a measurable reduction in infrequent failures. Findings should be interpreted accordingly.

Once the results have been reviewed, prioritise further installations according to asset criticality, environmental suitability and demonstrated operational value. This provides a repeatable approach to extending monitoring across the facility without assuming that every asset requires the same level of instrumentation.

Before proceeding with a NEON non-Ex deployment, confirm that the team has:

Automotive manufacturers depend on reliable equipment to maintain production schedules, protect product quality and control operating costs. Wireless condition monitoring can extend visibility of selected assets, particularly where conventional monitoring is limited by access, cabling requirements or the frequency of manual inspections.

IMI TWTG NEON non-Ex sensors provide options for vibration, temperature and pressure monitoring in suitable non-hazardous industrial environments. Their battery-powered operation and LoRaWAN connectivity offer a practical way to introduce additional measurement points without necessarily installing new signal cabling or external power supplies.

The most effective deployment starts with a clearly defined maintenance problem, a suitable sensor and a controlled pilot. By combining appropriate measurements with engineering judgement, verified communications and established maintenance workflows, automotive manufacturers can assess where additional condition information can support more effective asset management.

Stephen Howes is Product Manager, Connected Devices, at IMI.

Whether you are evaluating a pilot project or looking to extend condition monitoring across multiple production lines, our specialists can help identify suitable assets, select appropriate sensor technologies and design a monitoring strategy aligned with your maintenance objectives.

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