Wireless smart sensor issues and how to overcome them!

Wireless smart sensor issues and how to overcome them!

This article explains how to avoid all smart sensor issues and increase industrial efficiency, safety, and sustainability. Digitalization is vital to staying competitive, yet many companies abstain due to upgrading troubles. Read on to stay one step ahead of your competitors.

El-Watch is a developer of wireless smart sensor solutions in the industrial sector. We’ve been at it for more than twenty years. Along the way, we’ve encountered any sensor issues you can think of and subsequently overcame them.

Our current line of wireless sensors is as trouble-free as can be. Let’s go through the most common smart sensor issues and explain how our Neuron IoT Sensors can help you overcome them.


  1. Smart sensor installation is troublesome
  2. Wireless sensor functionality is limited
  3. Too many sensor-network upgrades
  4. Connectivity issues (Cloud/IoT/Wireless)
  5. Smart sensor inaccuracy under harsh conditions
  6. Insufficient cybersecurity
  7. High sensor network energy consumption
  8. Sensor administration drains company resources
  9. Smart sensors are too expensive
  10. How to avoid common wireless smart sensor issues?

Smart sensor installation is troublesome

Smart sensors for wireless IoT monitoring in the industrial sector have come a long way. Not so many years ago, they were clunky to operate and hard to install. Unfortunately, the market still overflows with old-fashioned and impractical sensor variants.

Our sensors are designed for easy application. Anyone can install our sensors; no machine or equipment retrofitting is required. Many of our wireless sensors attach by magnet or adhesive tape, while others simply attach by tightening a bolt.

Wireless sensor functionality is limited

The lack of specifically tailored sensors is a thing of the past. Over the last decade, the selection of wireless IoT sensors has exploded. More and more industry processes are automated, and functional smart sensors enable this development.

El-Watch offers more than 50 sensor variants for all kinds of industrial monitoring. Among our more popular sensors are Neuron Vibration, Neuron Temperature, Neuron Gauge Pressure, and Neuron Humidity.

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Find the perfect sensor solution

We offer over 50 different sensor types. Explore the possibilities in our product brochure.

Too many sensor-network upgrades

Due to the constantly improving sensor technology, some sensor upgrades are recommended. However, El-Watch has made upgrading your smart sensor network much easier and cheaper.

For one, our line of Neuron sensors is very robust. We rarely change smart sensors due to wear and tear. Wireless sensors run on batteries, though, which means that most of our sensors have about a ten-year lifespan.

In other words, you’ll likely upgrade to new and improved technology before the sensors break. Should you need to upgrade your sensor network, our wireless sensors are easy to install, and our IoT software aids you with placement and calibration.

Connectivity issues (Cloud/IoT/Wireless)

The dawn of IoT and cloud technology was plagued with connectivity issues. That said, the wireless sensor technology of today is a godsend since cables complicated installation and drove the monitoring prices through the roof.

Wireless sensors are cheaper, easier to install, and have become just as reliable. On top of this, maintaining, analyzing, and surveilling sensor networks is more convenient than ever with El-Watch’s Neuron Sensor app. Alternatively, you can apply our extensive selection of APIs to your own control system.

The app shows you a «map» of your sensors, gateways, and system users. For easy reading, you can rename your sensors, tag them in groups, and add placement pictures.

Smart sensor inaccuracy under harsh conditions

Outdated sensor technology can cause inaccurate readings, especially under industrial stress. On the other hand, an updated sensor network with the latest sensors on the market tends to provide incredibly accurate readings.

The exception is if the sensors are incorrectly installed or calibrated. This can affect monitoring accuracy. That said, the latest smart sensor networks on the market are becoming nearly foolproof. A faulty installation has become a rare occurrence.

Most of our sensors measure data every few seconds and report every few minutes. All these readings and statistics are stored in the cloud and are always available in your app. Measured anomalies are immediately reported, and alarms are set off on your devices.

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Insufficient cybersecurity

The emergence of IIoT (the industrial internet of things) brought new cybersecurity concerns. As larger amounts of data started to get processed in the cloud, security and privacy became bigger issues.

At El-Watch, we take cybersecurity very seriously. All gateway data is delivered via MQTT with TLS encryption. Likewise, all app and API traffic goes by HTTPS over TLS.

All data storage is protected by database AES encryption. We also use a two-step verification sign-in protocol to prevent password misuse by unauthorized personnel.

High sensor network energy consumption

Compared to industrial monitoring a decade ago, energy consumption has decreased considerably. Still, the size of industrial smart sensor networks accumulates considerable power surges, not just from hardware but from data processing.

Paradoxically, sensors meant to monitor and limit industrial energy use might use too much power themselves. The problem is not so much the energy cost but keeping the wireless sensors sustained for many years.

Luckily, this is not an issue with El-Watch’s sensors. They are designed to minimize computation power requirements in the sensors themselves, which makes the batteries last about ten years before depletion.

Sensor administration drains company resources

Setting up and administering large sensor networks takes a bit of finesse, but lately, the process has become manageable with very little training. Anyone can install El-Watch sensors; administration via our Neuron Sensor app isn’t rocket science.

Granted, there are many smart sensors to keep track of in large IIoT networks. Our app gives you a complete overview and makes it easy to keep tabs on all operations. Once you get the hang of it, any company’s saving and gaining potential is huge.

For instance, the app tells you how hard you can push your equipment without causing it damage. It also aids you in minimizing energy consumption, implementing predictive maintenance, and detecting equipment anomalies or dysfunctions.

The large selection of different sensor variants at El-Watch allows most customers to have a one-stop-shop solution for all IoT sensors, reducing the need to deal with many different IoT and cloud providers.

Get started with Neuron sensors from El-Watch

Smart sensors are too expensive

As mentioned, many sensor issues from the past have already been solved. Sensor installation used to be costly, especially when it required wiring. However, the latest wireless sensors on the market cost a fraction of the price and take much less time to install.

In the last 15 years, the average price of IoT sensors has dropped by almost 70 percent. Additionally, there have been many tools developed for setting up functional infrastructures for industrial smart sensor deployment.

In other words, the investment-return (ROI) balance has shifted. Smart sensors are a sound investment since they are relatively cheap to buy, quick to install, and designed to improve business efficiency.

Any industry with opportunities for automation will get a good return on wireless sensor investment. Get in touch with El-Watch to find out how your company can get less wasteful and more efficient with smart sensor implementation.

How to avoid common wireless smart sensor issues?

It is simple! Let El-Watch take care of your industrial monitoring needs, and your wireless sensor issues will be a thing of the past. These are the five best advantages you get from choosing El-Watch wireless IoT sensors:

  1. Robust sensors designed for industrial purposes
  2. Easy and flexible sensor installation
  3. Sustainable monitoring, no throwaway
  4. A wide selection of sensors for specific needs
  5. Secure and manageable data collection

Customer success story: El-Watch sensors prevented timber mill breakdown!

Ready to try wireless sensors?

Please contact our Sales Manager for some good advice and a nice sensor- chat.


Encyclopedia.pub: Architecture and Challenges of Industrial Internet of Things
Fierce Electronics: How to Avoid The Five Most Common Sensor Malfunctions
Heraeus: Sensor Challenges in Future Markets
IntechOpen: Wireless Sensor Networks: Applications and Challenges
IRJET: Challenges and issues in wireless sensor network – A review
MDPI: Intelligent Sensors in the Industry 4.0 and Smart Factory
SSRN: Evolution of IoT to IIoT: Applications & Challenges

What is a smart sensor used for?

A smart sensor is used for various applications, including monitoring and controlling industrial processes, environmental sensing, healthcare monitoring, and building automation. It combines sensing capabilities with data processing, communication, and decision-making functionalities to provide accurate, real-time information and improve system efficiency.

What is the difference between sensors and smart sensors?

The main difference between traditional sensors and smart sensors is that smart sensors have built-in processing capabilities. Traditional sensors typically collect data and send it to a central processor, whereas smart sensors can process data locally, making them more efficient and capable of real-time analysis and decision-making.

What is smart sensing technology?

Smart sensing technology refers to the integration of sensing elements with advanced processing and communication capabilities. This technology enables sensors to perform complex functions such as data analysis, pattern recognition, and autonomous decision-making, leading to more intelligent and responsive systems.

How does a smart sensor communicate data?

A smart sensor typically communicates data using various communication protocols such as Wi-Fi, Bluetooth, Zigbee, and IoT-specific protocols like LoRaWAN and NB-IoT. These communication capabilities allow a smart sensor to transmit data to central systems, cloud platforms, or other devices for further analysis and action.

Can a smart sensor be integrated with existing systems?

Yes, you can often integrate a smart sensor with existing systems. Designers ensure compatibility with various industrial protocols and standards, making it possible to retrofit into current setups. This integration enables enhanced monitoring, control, and data analysis without the need for complete system overhauls.

What industries benefit the most from smart sensors?

Several industries benefit significantly from smart sensors, including manufacturing, healthcare, agriculture, automotive, and smart cities. In manufacturing, a smart sensor improves automation and predictive maintenance. In healthcare, it enables patient monitoring and diagnostics; in agriculture, it aids in precision farming; in automotive, it enhances vehicle safety and performance. Smart cities use it for infrastructure monitoring and efficient resource management.

What are the disadvantages of smart sensors?

While smart sensors offer numerous advantages, they also have some disadvantages, including higher costs (while the installation tends to be cheaper), complexity in design, potential issues with interoperability, and the need for regular updates to ensure optimal performance.


Further reading