ManufacturingHardwareRobotics

Ep. 93 | Sensors Insights: Bridging Hardware Collection and Software Analysis

All About Circuits
All About Circuits•Apr 21, 2026

Why It Matters

A pragmatic, sensor‑first IoT roadmap reduces implementation risk, speeds digital transformation, and unlocks measurable efficiency and sustainability gains for manufacturers.

Key Takeaways

  • •Start IoT projects with simple monitoring before predictive maintenance.
  • •Leverage existing sensors first; add new ones only when necessary.
  • •Bridge hardware and software expertise to overcome skill gaps.
  • •Use incremental, agile steps to demonstrate quick ROI and gain buy‑in.
  • •Focus sensor data on sustainability, OEE, and consumption tracking.

Summary

The episode spotlights Emerson’s Niels Beckman discussing the "floor‑to‑cloud" industrial IoT journey, emphasizing that sensors are the foundational data source for any digital transformation. Beckman explains how Emerson blends hardware connectivity with software analytics to turn raw sensor signals into actionable insights for sustainability, productivity, and equipment effectiveness. Key insights include a recommendation to begin with simple monitoring rather than jumping straight to predictive maintenance, leveraging existing PLC‑linked sensors whenever possible, and only adding new hardware when specific data gaps—such as energy or airflow measurements—are identified. The conversation also highlights the biggest hurdle: aligning hardware engineers and software developers, a skill‑set mismatch that often outweighs pure budget concerns. Beckman notes, "Sensors are the core because they provide the data that fuels AI and sustainability goals," and cites real‑world examples like using existing position sensors for anomaly detection or installing energy meters to track consumption for green initiatives. He stresses an agile, step‑by‑step rollout—starting with a small, high‑impact use case, visualizing data, then iterating toward deeper analytics. For manufacturers, the takeaway is clear: adopt a pragmatic, sensor‑first IoT strategy, build cross‑functional teams, and demonstrate quick wins to secure stakeholder buy‑in. This approach minimizes cost, accelerates ROI, and positions firms to meet evolving efficiency and sustainability targets.

Original Description

Nils Beckmann, Director of Engineering for Intelligent Automation at @EmersonCorporate shares his insights on properly utilizing sensor hardware and application software to meet the challenges of the automation industry.
The "old school" way was simple: a sensor sees a part, tells the controller, and the actuator moves. It was pure hardware logic, and it worked. But in today’s smart factories, that’s only half the story.
Modern #sensors aren't just on/off switches anymore—they are eyes and ears, and sometimes even the brains, of the automation. However, surprisingly few engineers really understand both the hardware and software sides of machine data.
In this episode of the Moore’s Lobby podcast, Control.com’s David Peterson discusses sensors with Nils Beckmann, an expert with a background in both sensor hardware and IIoT software analytics. They explore the various solutions and best practices that ease the pathway to productively using sensor information.
Emerson has been a leader in measurement instrumentation for over 50 years. They have a broad portfolio of measurement and analytical instrumentation, software, integrated systems, and services.
For more information, as well as all the latest All About Circuits projects and articles, visit the official website at https://www.allaboutcircuits.com/

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