What are process sensors used for in industrial installations?
Sensors are components that convert physical inputs (such as weight, pressure, etc.) into an electrical measure. In industrial automation, process sensors play a key role in maintaining stable, efficient and safe operations by enabling accurate monitoring of key process parameters.
They help manufacturers monitor critical operating conditions, improve machine reliability and support predictive maintenance in automated systems.
SMC’s pneumatic sensors and switches will help you quantify and monitor the different parameters in your installation, maximising the productivity and efficiency of your processes while supporting equipment longevity and helping control energy consumption. Our products will help you carry out effective maintenance of your installation.
At SMC, we guarantee reliability and detail. Our industrial sensors and switches are engineered for precision, durability and seamless integration into modern automation environments, including IO-Link-enabled systems for smart factory applications. Discover the sensors and switches available in our digital catalogue and select the sensor that suits you best: improve process precision and operational efficiency.
Types of SMC sensors and switches
Here, you can find the different sensor and switch types that we offer at SMC and learn more about their different applications and technical specs.
Flow sensors
Digital flow sensors can monitor gas or liquid flow with precision. These products give you real-time and detailed information such as flow rate, accumulated flow rate, peak/bottom values, consumption of non-operation periods (leakages) and temperature. They help ensure stable and energy-efficient operation by monitoring air, water or coolant flow in real time.
Highlights:
- Highaccuracy flow measurement for gases and liquids
- Thermal and bypasstype sensing technologies
- IOLink models for advanced diagnostics
- Ideal for cooling circuits, pneumatic lines, dosing and process monitoring.
Liquid and gas flow sensors are common in applications such as:
- Equipment flow control
- Main lines or branch lines
- Gas filling
- Nitrogen flow control
- Air leakage detection
- Fluid rate control of thermo-chillers
- Flow control for pressurised cooling water for welding guns
- Flow control for water-soluble coolant
- Flow control for cooling water for metal moulds
- Dosing systems
- Process monitoring in industrial production lines
…and many more.
Pressure sensors and switches
Digital pressure sensors monitor application pressure accurately, helping to minimise the risk of switching errors and ensuring stable process performance.
SMC pressure sensors are available for positive, vacuum and compound pressure, allowing them to adapt to a wide range of industrial applications.
Accurate pressure measurement is essential for safe and efficient operation as SMC pressure sensors and switches convert pressure values into reliable electrical signals for real-time monitoring and control.
Pressure sensors and switches are commonly used in applications such as:
- Pneumatic systems and actuators
- Compressors and air preparation units
- Hydraulic circuits
- Leak detection systems
- Coolant pressure control
- Filter clogging monitoring
- Process control in manufacturing lines.
Key benefits of pressure sensors and switches:
- High precision and repeatability
- Wide pressure ranges: vacuum (–100 kPa), low pressure and high pressure (up to 50 MPa)
- Digital and analogue outputs (PNP, NPN, IOLink, 1–5 V) to identify potential failure sources and reduce machine downtime
- IP40, IP65 and IP67 protection options
- Peak pressure detection, leak monitoring and early warning alerts
- Userfriendly displays and simple configuration.
Vacuum sensors and switches
Vacuum sensors and switches also monitor vacuum levels accurately. Reliable vacuum detection is essential in pick-and-place, packaging and handling applications, where secure gripping and safe operation are critical.
SMC vacuum sensors provide a fast response and stable readings, helping ensure consistent performance and early detection of insufficient vacuum conditions.
Vacuum sensors and switches are commonly used in applications such as:
- Pick-and-place systems
- Packaging machinery
- Robotic gripping applications
- Vacuum handling systems
- Workpiece placement verification
- Leak testing
- Material handling and transfer systems.
Key features of vacuum sensors and switches:
- Precise vacuum level monitoring
- Digital and analogue outputs
- Compact designs for robotic and compact machinery
- Early detection of leaks or insufficient vacuum.
Auto switches
Auto switches are designed for pneumatic and/or electric cylinders and grippers, which incorporate magnets in their piston rods to detect their own position.
The exact location is detected through the cylinder or gripper wall. As auto switches are non-contact devices, they are wear-resistant and therefore guarantee a high level of operational reliability.
Some of their advantages are:
- Wide range of mounting styles for SMC actuators
- Highsensitivity magnetic detection
- LED indicators for easy status checking
- Durable, compact and resistant to shock and vibration.
Auto switches are typically used in applications such as:
- Pick-and-place machines
- Length/width discrimination
- Inspection of machined holes
- Dimension measurement
- Product position verification.
Temperature sensors
Temperature sensors are designed for applications requiring thermal stability and additional process monitoring within industrial automation systems.
Temperature monitoring in SMC sensing solutions supports humidity control, condensation prevention and stable operating conditions in pneumatic systems.
Typical applications include:
- Cooling circuit monitoring
- Thermo-chiller systems
- Temperature control in fluid handling processes
- Machine condition monitoring.
Why choose SMC process sensors and switches?
SMC’s wide range of sensing solutions are used across almost all industries worldwide. They help maintain stable, efficient and safe industrial operations by providing accurate measurement for pressure, flow, vacuum and position detection across a wide variety of applications. These are just some of the many aspects you can benefit from:
- Diverse range: We offer a wide variety of enclosures, pressure, vacuum, flow rate and position sensing ranges, allowing you to select the right sensor for different industrial processes and installation requirements
- Easy control of your process: Most of our sensors have 3 visible parameters on the screen and red/green colour values to make acceptable range identification easier, helping operators monitor conditions quickly and maintain optimal system performance
- Easy programming: Take advantage of our 3-step setting which makes setting up a sensor extremely easy. You can complete the configuration in just three simple clicks. This simplifies installation and reduces commissioning time for new or existing systems
- Product diagnostics with Smart connectivity for Industry 4.0: Detect issues within the equipment using the cyclic (cycle) data and also monitor such issues in detail with the monocyclic (periodic) data thanks to IO-Link compatibility, enabling real-time diagnostics, remote configuration and predictive maintenance while reducing manual intervention
- Built for industrial reliability: Our sensors are designed with a robust construction to withstand demanding environments, vibration, moisture and continuous industrial duty cycles
- Easy installation and flexible mounting: Compact designs, intuitive interfaces and multiple mounting options make integration straightforward across different machine layouts.
How do SMC process sensors improve your operations?
- Greater efficiency: Realtime data helps optimise air consumption, reduce waste and improve cycle times
- Higher machine uptime: Early detection of leaks, blockages or abnormal pressure/flow conditions prevents failures and unplanned downtime
- Better product quality: Stable process conditions ensure consistent output and reduce variability
- Futureready automation: IOLinkenabled sensors support predictive maintenance and smart factory strategies.
How to choose the right process sensor
Monitoring your different installation parameters is the key to moving towards the Smart flexibility and Energy efficiency required in modern industry.
Selecting the right process sensor plays an important role and depends on:
- Measurement type: pressure, flow, vacuum, position, temperature
- Operating range: vacuum, low, medium or high pressure/flow
- Output signal: analogue, digital, IOLink
- Environmental conditions: IP rating, temperature, vibration
- Display & interface needs: local monitoring vs. remote control.
Last but not least, you must be aware of the importance of industrial maintenance to prevent potential issues, save costs and improve the efficiency of production lines.
Take advantage of our sensors and switches and get help selecting the one that best suits your needs thanks to the Digital Switch Model Selector in the Engineering Tools section of our website.
Need help selecting the right process sensor?
If you’re unsure which sensor best fits your application, don’t hesitate to get in touch with our technical specialists who will help you evaluate your requirements and recommend the ideal solution for your installation.
Frequently Asked Questions about process sensors
How do I know which type of sensor is best for my application?
The right sensor depends on the variable you need to measure (pressure, flow, vacuum, etc.), the operating range, the required output signal (analogue, digital, IOLink) and the environmental conditions of your installation. SMC’s Digital Switch Model Selector can help you quickly identify the most suitable model based on your application parameters.
What advantages does IOLink offer for process sensors?
IOLink enables advanced diagnostics, remote configuration and continuous monitoring of sensor performance. This improves predictive maintenance, reduces downtime and simplifies commissioning — making it ideal for Industry 4.0 and smart factory environments.
What industries typically use process sensors?
Process sensors are widely used in industries such as:
They support applications ranging from pneumatic control and leak detection to dosing, cooling and machine safety.
Are SMC sensors suitable for harsh or demanding environments?
Yes. Many SMC sensors are available with IP65 or IP67 protection, vibrationresistant housing and robust construction designed for challenging industrial conditions. This ensures long service life, even in environments with dust, moisture or mechanical stress.
Are SMC sensors compatible with PLCs and industrial networks?
Yes. SMC sensors support common industrial outputs and communication standards, including PNP/NPN, analogue signals and IOLink, ensuring seamless integration with PLCs and automation systems.
