When the sensors work as expected, people barely notice their existence, and people only think that without these sensors, the system will not be able to achieve the advantages. However, sensors can sometimes fail, and at this point, customers feel that their investments have been squandered, losing their trust in sensor suppliers and their brands. Below are five common sensor failures that can occur and how to resolve and eliminate them.

1. Wrong reading due to improper installation

Many people are trying to confirm that the sensor is undergoing an iterative process cycle during normal operation. They do this because they usually take it for granted that the reason why the test is not working properly is that the sensor itself has problems, such as problems with the internal wiring of the sensor.

However, if the installation method is not correct, it will cause abnormal readings. For example, a sensor that detects the presence of metal cannot adhere to the metal being inspected, and there must be a certain space between the sensor and the metal surface it is to identify, which may result in incorrect readings. The easiest solution to this type of failure is to change the mounting position of the sensor.

2. Calibration drift in the pressure sensor

Food and beverage companies often use pressure sensors in their factories to ensure that the production environment complies with relevant regulations and quality standards. However, if condensation occurs on the pressure sensor, it may cause a given calibration failure, or "calibration drift." When this happens, the worker operating the production equipment based on the data of the pressure sensor may not know that a failure has occurred. In some cases, calibration failure or failure to calibrate can result in a disruption in the production process.

In environments where instrument calibration is necessary and calibration must be guaranteed, many customers choose pressure sensors that are less likely to experience calibration drift. In addition, engineers can deploy airflow systems to promote air flow to prevent condensation.

3. Printed circuit board (PCB) problems

Printed circuit boards (PCBs) are an essential component of many popular electronic products, such as smartphones and IoT devices. However, if PCB manufacturers and designers do not pay attention to the PCB and any sensors around it, it is likely to cause product failure. First, for most PCBs, it is best to avoid routing at 90 degrees because this type of wiring tends to increase electromagnetic interference, and excessive electromagnetic interference can cause product defects.

In addition, the use of manufacturability design (DFM) helps PCB manufacturers avoid problems that may arise during production. Perform a manufacturability design check on the PCB to check if the device layout on the PCB could damage the manufacturing and assembly process. For example, when you use multiple sensors in an IoT device, remember that it is necessary to check the hot area of the PCB and evaluate possible temperature changes and whether this temperature rise will damage the sensor.

4. Failure due to network security vulnerabilities

In consumer electronics, IoT devices are the most common product category using sensors. Today's homes are quickly becoming accustomed to multiple IoT devices deployed in their homes, but one important issue here is that IoT devices often do not have or are seriously lacking in security measures.

A number of research reports from cybersecurity agencies indicate that IoT devices will face more attacks in 2019. A Avast publication predicts that the evolution of Internet of Things malware will make it more complex than the malware that has appeared in computers and smartphones in the past.

In addition, a Nokia study found that in 2018, IoT botnet activity accounted for 78% of the entire malware operator's network activity. Researchers are also concerned about hackers hacking into smart city sensors and causing serious damage to the entire community, rather than just staring at consumer devices. In a survey of three leading smart city sensor suppliers, 17 network security flaws were identified, with up to eight key vulnerabilities.

The findings suggest that sensor companies and customers have many known cybersecurity issues that have not yet been discovered, the risks are growing, and they need to be fully managed in the next few years. Engineers building IoT devices need to make cybersecurity a top priority throughout the design and production of sensors and other components to help reduce the impact of network security failures on the device.

5. Problems with the car's oxygen sensor due to low fuel quality or improper maintenance

Today's cars are equipped with a range of sensors, especially when these vehicles deploy some autopilot-related functions, including lane sensing or obstacle avoidance. In addition, there is a common tire temperature pressure sensor that tells people when it is necessary to adjust the pressure of the tire when the tire pressure is too high or too low to cause safe driving. However, there are also sensors that are not familiar to people, such as oxygen sensors. The oxygen sensor monitors the amount of oxygen in the exhaust gas. The sensor communicates the results to the car's computer using a voltage signal, and then, if necessary, the on-board computer adjusts the mixing ratio of the fuel/oxygen mixture delivered to the engine.

When the ratio of fuel to oxygen is not suitable, the mixture is too thin or too rich, which may cause the car to run unevenly, or fail to achieve the desired fuel efficiency, resulting in an increase in fuel consumption per 100 kilometers. In addition, over time, the oxygen sensor may also be agglomerated by combustion by-products such as fuel additives and putty. Failure to perform regular maintenance, especially if the spark plug and air filter are not regularly replaced as required by the manual, may cause problems with the oxygen sensor. In order to help promote complete combustion of the fuel in these devices, incomplete combustion can result in the accumulation of waste in the exhaust system.

If the driver uses undesired gasoline or inferior gasoline, the life of the oxygen sensor may also be lower than the expected average life. The car manufacturer will provide information on the use of the oxygen sensor in the vehicle manual to help the owner avoid the oxygen sensor failure. For example, it is generally recommended to replace the oxygen sensor when driving between 60,000 and 90,000 miles in a car that is less than 15 years old.

Proactive consideration and early prevention can reduce sensor failure

This article describes sensor issues that may occur during production or during work. When sensor manufacturers and customers consider in advance what failures can occur and prevent them, they can avoid sensor failures and normally serve customers' products.