Benefits of using energy harvesting sensors

Immediate benefits of using energy harvesting sensors

Are all equipment sensors the same? No, compared with plug-in or battery-operated sensors, energy harvesting sensors punch above their weight. As manufacturing industries implement the Industrial Internet of Things, self-powered sensors are becoming a rising star. DCO Systems explain the pitfalls of other power sources, the immediate benefits of energy harvesting sensors, and why you should make the switch.

DCO Systems offer a battery-free, energy harvesting monitoring solution. Energy harvesting sensors offer immediate benefits once installed.

Battery-operated sensors are finite and transmit data less

Most sensors used for monitoring machines are either powered by batteries or wired into existing infrastructure. However, the problem with battery-operated sensors is that batteries are finite. Notably, engineers always need to take into account ‘How much power do I have left?’. While the monitoring of temperature may not use a lot of power, in contrast radio transmissions or getting data to the engineer tends to be energy intensive. Therefore, for battery-operated sensors to have a long life, they often do less. This can include less transmitting of data or monitoring fewer performance metrics. As a result, you have only snapshots of your process and gaps in data gathering.

DCO Systems avoid the need for an electrical engineer and wires by offering energy harvesting sensors which include immediate benefits.

Plug-in sensors are reliant on infrastructure

Plug-in or wired sensors also come with challenges and limitations. Specifically, if a plant needs immediate monitoring solutions, your hands lie in the fate of getting a site engineer to wire in the energy points. In addition to the waiting, what about the places (tunnels, high up chimney stacks) that have little infrastructure or no access? Moreover, once wired sensors are installed in only accessible places, they rely on energy and add to your ongoing energy costs. Consequently, the result is that you end up monitoring only a portion of your equipment.

DCO Systems offer benefits including maintenance-free, self-powering, energy harvesting sensors.

Battery-free, wireless sensors break through energy source barriers

The solution to these challenges is using ambient energy, from natural or process sources, to power sensors and collect data. Notably, the simplest description of this is sensors with solar panels on them, which collect and store energy from both natural and artificial light. Furthermore, other examples include energy gathered from temperature differential, changes in temperature within a room, or energy gathered from the vibration or acoustics of an operating machine. All these elements generate energy and DCO Systems have developed a sensor that harnesses this energy, without the need for batteries or wires. Consequently, the sensor units are self-powering and because there is an infinite duration of an ambient energy source available, they can be used nearly anywhere, even in places with little infrastructure or access. 

Easy installation and deployment

Further benefits include easy installation, simplified with colour coordinated fittings and adapters; immediate use, can be up and running the next day; and maintenance-free, once installed the sensors can run infinitely without the need for battery changes. Self-powered sensors also store energy which means they always have the power to transmit data as frequently as needed. This allows you to fill in data gaps and create a rich and robust data set for your machines. Equally important, DCO’s self-powered sensors are able to monitor more components at one time. One client recently enjoyed monitoring temperature, vibration and electrical analysis in parallel and this gave them significantly more insight into their ageing motors and drive system.

Problems that occur with battery-operated or wired sensors can be eliminated completely. It's clear why energy harvesting sensors are the rising star, isn’t it time you made the switch. Data can be gathered more frequently, in more places, with more metrics being monitored using DCO’s battery-free, wireless sensors. To get started with DCO’s affordable monitoring tools, contact page or email us at

3 Global Business Park
14 Wilkinson Road
Cirencester GL7 1YZ
United Kingdom

+44 (0)1285 359059

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