In real-world applications, sensors do not operate in laboratory conditions.
Vibration, moisture, dust, extreme temperatures, and electromagnetic interference turn measurement into a complex engineering challenge. Selecting the wrong sensor can lead to system failures, unexpected downtime, increased maintenance costs, and safety risks.
In our previous article, we explained why measurement must be treated as a system rather than a single component.
👉 Read here:
When Measurement is a System – Not a Component
This article moves to the next step: how to select sensors that maintain accuracy and reliability in harsh operating environments.
Why Sensors Fail in the Field
What performs perfectly on a test bench may fail quickly in real operating conditions.
Common failure factors include:
Vibration and shock
Cause mechanical wear, loosen connections, and damage internal components.
Water and moisture ingress
Lead to corrosion, short circuits, and measurement drift.
Dust, mud, and contamination
Compromise sealing and interfere with moving parts.
Extreme temperatures
Cause drift, material expansion, and accelerated component aging.
Electromagnetic interference (EMI)
Can distort signals and create inaccurate readings.
Mechanical stress
Improper mounting or side loads significantly shorten service life.
Critical Parameters When Selecting a Sensor
✔ Environmental sealing & IP rating
Outdoor environments, washdowns, and mud exposure require IP67/IP68 protection.
✔ Vibration and shock resistance
Mobile equipment, heavy machinery, and off-road platforms require rugged construction.
✔ Operating temperature range
Sensors must match real environmental extremes, not just nominal operating ranges.
✔ Mechanical durability & mounting integrity
Proper mounting design, strain relief, and side-load protection directly impact longevity.
✔ EMI immunity
Industrial, automotive, and defense environments demand robust signal integrity.
Matching Sensor Type to the Application
Position Sensors
Used for motion control, automation systems, and mobile equipment.
Pressure Sensors
Critical in hydraulic systems, heavy equipment, and industrial processes.
Temperature Sensors
Enable thermal monitoring and equipment protection in harsh environments.
Tilt Sensors
Essential for vehicle stability, mobile platforms, and autonomous systems.
Common Engineering Mistakes
❌ Selecting sensors based only on accuracy
❌ Ignoring environmental conditions
❌ Improper sealing design
❌ Poor mechanical installation
❌ Neglecting cable protection and routing
❌ Underestimating vibration and shock loads
In many cases, failures are caused by improper application — not by the sensor itself.
In Harsh Environments, Reliability Matters More Than Accuracy
In real-world conditions, durability and stability are just as important as nominal accuracy.
A sensor that maintains stable performance under extreme conditions delivers greater system value than one offering higher precision but limited survivability.
How Variohm EuroSensor Solutions Address Harsh Environments
Variohm EuroSensor specializes in sensor solutions designed for demanding environments across industrial, transportation, mobile equipment, and defense applications.
Key strengths include:
-
Rugged designs for harsh operating conditions
-
High environmental protection and sealing
-
Long-term measurement stability
-
Multiple sensing technologies for application flexibility
-
Customization options for specialized requirements
This approach enables engineers to design reliable measurement systems even in the most demanding environments.
Typical Applications in Harsh Conditions
✔ Agricultural and off-road equipment
✔ Autonomous and robotic systems
✔ Defense platforms
✔ Heavy industrial machinery
✔ Mobile hydraulic systems
✔ Mining and earth-moving equipment
Conclusion
Selecting a sensor for harsh environments is not a catalog decision – it is a system-level engineering choice.
By matching the sensor to real environmental conditions, designing proper installation, and treating measurement as part of a complete system, engineers can ensure long-term reliability, stability, and reduced maintenance costs.
Future articles in this series will explore specific sensor types and application considerations in greater depth.