Industrial sensors fail for several reasons, including environmental stress, electrical problems, mechanical wear, and contamination. Temperature extremes, power surges, vibration, and age-related component degradation are the most common culprits. Recognising early warning signs and understanding repair versus replacement options helps maintain equipment uptime and control costs.
What causes sensors to fail in industrial equipment?
Industrial sensors fail due to multiple interconnected factors that stress these precision devices beyond their operational limits:
- Environmental factors – Temperature fluctuations, humidity, and constant vibration gradually degrade sensor components, with extreme heat accelerating ageing whilst freezing conditions crack housings
- Electrical issues – Power surges, electromagnetic interference, and voltage spikes damage delicate circuitry either instantly or through gradual performance decline
- Contamination damage – Dust, chemicals, oils, and particulates block optical sensors and corrode electrical contacts, disrupting signal transmission
- Mechanical wear – Moving parts deteriorate over time whilst vibration loosens connections and stresses internal components
- Age-related degradation – Electronic components naturally deteriorate as capacitors lose capacity, resistors drift from specifications, and solder joints develop micro-fractures
- Installation and maintenance issues – Poor mounting practices, inadequate environmental protection, and lack of preventive care accelerate all failure modes
These failure mechanisms often work in combination, creating cascading effects that compromise sensor reliability. Understanding these root causes enables better prevention strategies and helps determine whether specific failures warrant repair or replacement, ultimately supporting more effective maintenance planning and cost control.
How can you tell when an industrial sensor is failing?
Detecting sensor failure requires systematic monitoring of both performance indicators and physical condition:
- Signal anomalies – Erratic readings, unexpected fluctuations, or measurements that don’t correspond to actual process changes indicate internal malfunctions
- Gradual drift – Slow changes in readings over weeks or months, often noticed when comparing multiple sensors measuring the same parameter
- Intermittent operation – Occasional signal loss or erratic behaviour that comes and goes under similar operating conditions
- Physical deterioration signs – Damaged cables, corroded connections, cracked housings, moisture intrusion, or visible contamination on sensor surfaces
- Complete signal loss – Total failure to respond or provide output despite proper power supply and connections
- Calibration discrepancies – Readings that consistently differ from reference instruments or fail to match known process conditions
Professional diagnostic approaches include comparing readings with calibrated references, checking electrical continuity, measuring supply voltage stability, and monitoring signal patterns over time. Early detection of these warning signs enables proactive maintenance decisions, preventing unexpected failures that could disrupt operations and allowing for planned repair services during scheduled maintenance windows.
What’s the difference between repairing and replacing failed sensors?
The choice between sensor repair and replacement involves several critical considerations that impact both immediate costs and long-term performance:
- Cost implications – Repair typically costs 40-70% less than replacement, making it attractive for expensive sensors with localised damage
- Time factors – Repair often provides faster turnaround than procurement of new equipment, reducing operational downtime
- Performance expectations – Properly executed repairs can restore original specifications, whilst new sensors guarantee maximum reliability with full warranty coverage
- Compatibility considerations – Repaired sensors maintain exact compatibility with existing systems, whereas replacements might require recalibration or system modifications
- Long-term reliability – New sensors offer extended service life and full manufacturer support, whilst repaired units may have shorter warranty periods
- Technology currency – Replacement allows upgrading to newer technology with enhanced features, whilst repair preserves existing functionality
The optimal decision depends on sensor criticality, failure analysis results, total cost of ownership projections, and operational impact tolerance. Critical safety systems often warrant replacement for maximum reliability, whilst process monitoring applications may benefit from cost-effective repairs when failure analysis indicates repairable damage, supporting both operational continuity and budget management objectives.
How MT Unirepair helps with sensor failures
We specialise in component-level sensor troubleshooting and repair, identifying root causes of failures rather than surface-level fixes. Our engineering team handles diverse sensor types from delicate electronic components to complex electromechanical assemblies, using precision restoration techniques that address both immediate malfunctions and underlying performance degradation.
Our comprehensive sensor repair services include:
- Comprehensive diagnostic testing – Advanced analysis to identify failed components like resistors, diodes, or connectors using precision measurement equipment
- Component-level repairs – Specialised restoration of temperature, pressure, flow, and proximity sensors with exact specification replacement parts
- Circuit board repair and refurbishment – Complete restoration of sensor control electronics including trace repair and component replacement
- Calibration and performance verification – Rigorous testing against industry standards to ensure accuracy and reliability meet original specifications
- Quality assurance testing – Comprehensive validation of performance, safety, and reliability parameters before return to service
Our systematic approach combines rapid diagnosis with expert repairs using quality replacement parts that meet or exceed original manufacturer specifications. This comprehensive methodology ensures restored sensors perform at levels comparable to new devices whilst maintaining compliance with industry regulations, providing reliable operation you can trust for critical applications.
This comprehensive repair capability helps you maintain operational continuity whilst reducing capital expenditure by 40-70% compared to new sensor purchases, supporting both operational excellence and sustainability objectives through extended equipment lifecycles.
If you are interested in learning more, contact our team of experts today.
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