Test and measurement is an essential step to ensure safety, quality, and productivity of all manufactured products.

 

As management Guru Peter Drucker put it famously, ‘if you can’t measure, you can’t improve it’. Whether in discrete manufacturing or process industries – measuring the parameters or testing the equipment is of utmost importance to check accuracy, precision, consistency, safety and for quality control. Not just in industry, but in every aspect of human life, testing, inspection and monitoring plays a critical role in ensuring day-to-day safety and quality of life. What started with basic hand measurements in terms of fingers and outstretched palm size has today metamorphosed into sophisticated electronic devices for exact measurements. So what are the current trends and innovations in the test and measuring instruments industry?

 

 

“The test and measurement instruments industry is buzzing with exciting innovations and trends. Industry 4.0 and IoT integration are bringing smart, connected systems to life, enabling real-time data monitoring and analytics. Modular and software-defined instruments are winning favour for their unmatched flexibility, scalability, and cost-effectiveness. Cutting-edge high-speed and high bandwidth testing capabilities are emerging to support the latest technologies and data interfaces,” says Sureshbabu Chigurupalli, Business Head (Ferro Alloys & Projects), Indian Metal Ferro Alloys (IMFA) Ltd. “AI and ML are revolutionising the field by enhancing data analysis, optimising test parameters, and enabling predictive maintenance. Environmental and EMC testing are critical for ensuring product reliability and regulatory compliance. Portable and field-deployable instruments are making on-site testing and troubleshooting more efficient than ever. The demand for wireless testing equipment that can handle higher frequencies and wider bandwidths is on the rise. The future of testing and measurement is here, and it’s smarter, faster, and more efficient than ever before,” he adds.

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Hemal Desai – Vice President Quality & Marketing Communications, Endress+Hauser India Pvt Ltd, draws attention to the fact that Endress+Hauser is at the forefront of innovation in the test and measuring instruments industry. Some of the key trends and the solutions developed by E+H to address them are:

• Increased demand for intelligent instruments that seamlessly integrate with digital ecosystems and provide real-time data for process optimisation and predictive maintenance – a comprehensive portfolio of IIoT-enabled instruments with features like Heartbeat Technology for self-diagnostics and remote monitoring capabilities

 

• Growing emphasis on optimising processes for reduced energy consumption, water usage, and waste generation – instruments with low power consumption and offer solutions for efficient resource management, such as flowmeters for precise control and leak detection systems.

 

• New sensor technologies for more accurate, reliable, and versatile measurements across various process parameters – R&D for innovative sensor technologies like ultrasonic flowmeters, tunable diode laser (TDLAS) analysers for gas composition measurement, and Raman spectroscopy for real-time process analysis.

 

• Heightened awareness of cybersecurity threats in industrial automation systems – Prioritising cybersecurity throughout the product life cycle, implementing robust security features and adhering to industry-standard protocols.

 

 “Endress+Hauser is committed to developing cutting-edge test and measuring instruments that empower customers to operate more efficiently, sustainably, and securely. By staying at the forefront of these trends, we aim to be your trusted partner in navigating the ever-evolving industrial landscape,” says Desai. 

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According to Wout van 't Wel, Communications Manager, Bronkhorst High-Tech BV, a prominent trend is the integration of multiple sensors within these devices, allowing for more comprehensive and precise measurements. These sensors, coupled with intelligent firmware, enable real-time data processing and advanced analytics, resulting in highly accurate and reliable performance. “Modern mass flow meters and controllers are becoming increasingly compact and user-friendly, facilitating easier integration into various applications. The use of digital communication protocols, such as EtherCAT, Modbus, and Profibus, enhances connectivity and interoperability with other industrial systems. This digital transformation is crucial for industries requiring stringent control over gas and liquid flows, such as semiconductor manufacturing, biotechnology, and chemical processing,” says Wout.

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How do regulations and standards influence the design and manufacture of test and measurement instruments?

 

“Regulations and standards play a critical role in the design and manufacture of test and measurement instruments, says Vilas Kulkarni, Managing Director, Baumer Technologies, and lists out the influence they wield on various aspects:

1. Ensuring safety and compliance

2. Ensuring accuracy and reliability

3. Interoperability and compatibility

4. Market access and global trade, and

5. Innovation and development.

 

“Regulations and standards are fundamental in shaping the test and measurement instruments industry. They ensure that products are safe, reliable, accurate, and compatible with other systems, while also facilitating global trade and driving technological innovation. Adhering to these standards not only helps manufacturers meet legal requirements but also enhances their reputation and competitiveness in the market,” Kulkarni emphasises. 

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For Gaurav Bawa, Sr Vice President, WIKA India, regulations and standards significantly impact the design and production of test and measurement devices in multiple ways. They set environmental and safety standards for hazardous situations, mandate calibration procedures for consistent performance, and enforce accuracy, dependability, and safety through compliance requirements. Standards facilitate interoperability by guaranteeing that instruments can be easily integrated into intricate testing configurations and international markets. Adhering to these rules is essential for guaranteeing product quality, dependability, and market access, as well as influencing how producers innovate and create these instruments. “At WIKA India, we ensure the instruments we develop align with various safety, reliability and performance criteria set by different industries. Our products also adhere to various international standards to ensure safety and comply with hygienic standards,” Bawa explains.

 

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“Due to rapid technological advancement, the T&M instrument industry is on an exponential growth path and transformation,” says Darshana Thakkar, Founder, Transformation – The Strategy HUB, as she outlines a few trends transforming this industry sector drastically. These include:

• Integration of IoT with the test and measuring instruments allows real-time data collection, remote monitoring, and improved connectivity.

• Intelligent Sensors with enhanced accuracy, sensitivity, and reliability provide precise measurements.

• AI and machine learning algorithms integrated into test and measuring instruments enhance data analysis, predictive maintenance, and anomaly detection.

• Wireless test and measurement tools are becoming more prevalent, offering flexibility and ease of use in various environments, including remote and hazardous locations.

• The rollout of 5G technology is capable of handling higher frequencies, wider bandwidths, and increased data rates.

• Modern instruments feature user-friendly interfaces with touchscreens, graphical displays, and customisable dashboards.

• The eco-friendly design reduced power consumption and sustainable materials.

• There is a trend towards multi-functional test and measuring instruments that combine several measurement capabilities into a single device, offering cost savings and improved versatility.

 

How do manufacturers/designers ensure the accuracy and reliability of their instruments against growing environmental concerns?

 

“In a world where environmental concerns are paramount, manufacturers and designers are rising to the challenge by creating instruments that not only excel in accuracy and reliability but also embody sustainability. By embracing eco-friendly design practices, cutting-edge technologies, and rigorous testing protocols, they ensure their instruments deliver precise measurements and monitoring capabilities. With the integration of environmental sensors and real-time data analysis, these instruments empower informed decision-making and sustainable practices. Committed to staying ahead of the curve, manufacturers collaborate with experts and continuously update their designs to address emerging environmental issues. The result? Instruments that not only measure the environment but also help preserve it for future generations,” says Sureshbabu Chigurupalli.

 

“At Endress+Hauser, we recognise the growing environmental concerns and their potential impact on the accuracy and reliability of test and measurement instruments. We take a multi-pronged approach to ensure our instruments continue to deliver trusted data in increasingly challenging conditions,” says Hemal Desai. According to him, these include:

 

1. Robust Design and Material Selection

We use high-grade materials that can withstand extreme temperatures, harsh chemicals, and exposure to UV radiation. This ensures the instruments' performance remains consistent even in harsh environments.

 

Our rigorous testing procedures simulate real-world conditions, including extreme temperatures, vibrations, and electromagnetic interference, to guarantee the instruments' functionality and data integrity.

 

2. Environmental Compensation Features

Many Endress+Hauser instruments come equipped with built-in environmental compensation features. For example, our pressure transmitters can automatically adjust for temperature fluctuations, maintaining measurement accuracy.

 

We actively develop new compensation algorithms to account for a wider range of environmental factors, ensuring reliable data regardless of external conditions.

 

3. Advanced Sensor Technologies

We invest heavily in research and development of advanced sensor technologies less susceptible to environmental variations. For instance, some of our flowmeters utilise ultrasonic technology, which offers excellent accuracy regardless of temperature or pressure fluctuations.

 

We explore new materials and designs for sensors to improve their resistance to environmental stressors and ensure long-term stability.

 

4. Regular Maintenance and Calibration

Regular maintenance and calibration are crucial for maintaining the accuracy and reliability of any instrument, especially in harsh environments. We provide comprehensive maintenance plans and user-friendly calibration tools to ensure our instruments perform optimally over their lifespan.

 

Additionally, some Endress+Hauser instruments feature self-diagnostic capabilities that alert users to potential issues before they can impact accuracy.

 

5. Collaboration and Knowledge Sharing

We actively collaborate with industry experts, research institutions, and regulatory bodies to stay informed about the latest environmental challenges and their potential impact on measurement technologies.

 

“At Endress+Hauser, our commitment to environmental responsibility goes beyond ensuring the accuracy of our instruments. We design instruments with low power consumption and develop solutions that promote resource efficiency, like flowmeters for leak detection and optimised water management systems. By prioritising these aspects, Endress+Hauser strive to deliver instruments that are not only accurate and reliable but also environmentally conscious. We believe in empowering our customers to make informed decisions based on trustworthy data while promoting sustainable practices within their operations,” Desai elaborates.

 

Wout van 't Wel explains how Bronkhorst ensures the accuracy and reliability of their mass flow meters and controllers through a robust approach that prioritises both precision and environmental responsibility. Obtaining environmental certifications such as RoHS (Restriction of Hazardous Substances) and REACH (Registration, Evaluation, Authorization, and Restriction of Chemicals) is a fundamental part of their strategy. These certifications affirm that Bronkhorst’s instruments comply with stringent environmental regulations, minimising the use of hazardous substances and ensuring safe and sustainable operation. “Bronkhorst’s commitment to accurate conversion and calibration processes plays a crucial role in enhancing the performance of their mass flow meters and controllers. By meticulously calibrating their instruments with the aid of the extensive FLUIDAT database (1800 fluids) and FLUICAL calibration software, Bronkhorst eliminates the need for using valuable or rare gases and liquids. This not only conserves these resources but also reduces environmental impact by preventing unnecessary emissions and waste,” informs Wout.

 

What are the advantages of virtual instrumentation over traditional hardware based systems; and how has digitalisation impacted the T&M scenario?

 

According to Vilas Kulkarni, virtual instrumentation offers several advantages over traditional test and measurement equipment:

1. Flexibility and scalability

2. Cost-effectiveness

3. Enhanced data analysis and processing

4. Remote monitoring and control, and

5. Simplified maintenance and upgrades.

 

Per him, the impact of digitalisation on the T&M scenario, can be broadly summarised as:

1. Improved accuracy and precision

2. Data integration and management

3. Enhanced user interfaces and user experience

4. Increased automation and efficiency, and

5. Real-time monitoring and predictive analytics.

 

“In summary, virtual instrumentation offers significant advantages over traditional hardware-based systems in terms of flexibility, cost-effectiveness, data analysis, remote capabilities, and ease of maintenance. Digitalisation further enhances the T&M landscape by improving accuracy, facilitating data integration, enhancing user experience, increasing automation, and enabling real-time monitoring and predictive analytics,” asserts Kulkarni.

 

“In the T&M industry, virtual instrumentation includes several advantages over classical hardware-based solutions. Firstly, the software based instruments offer advantages like flexibility and adaptability with their ability to provide software tools’ modification and reconfiguration without changing the hardware part. It is also easier to test new approaches of measurement as well as the new models and prototypes in a relatively shorter timeframe. Secondly, where virtual instrumentation is used components from commercial off the shelf (COTS) hardware and software are utilised making the process scalable, more cost efficient and having lower set-up and maintenance costs,” says Gaurav Bawa. “Moreover, with connectivity and IoT integration, digitalisation has transformed T&M as significant changes have taken place in terms of remote access, real time data collection as well advanced analytics,” he reasons. 

Darshana Thakkar feels virtual instrumentation offers significant advantages in flexibility, cost efficiency, integration, scalability, and advanced data processing capabilities. She summarises a few key benefits with the following points:

• Software-based configuration allows easy adaptation to different measurement and control needs.

• Cost efficiency is due to the reduced specialised hardware. General-purpose computers and standard interfaces often suffice.

• Software updates and maintenance are more cost-effective than servicing and calibrating multiple hardware components.

• Scalability is more due to the ease of upward or downward changes when adding or removing software modules.

• It has enhanced data processing and analysis due to real-time data processing, which performs real-time data analysis, signal processing, and visualisation.

• Virtual instrumentation systems can be accessed and controlled remotely via network connections, enabling centralised monitoring and diagnostics.

• Prototyping and development are quick for new systems using virtual instruments.

• Enhanced accuracy and reliability due to digital precision and error reduction due to manual calibration.

 

How is data generated by test and measurement instruments managed and utilised?

 

Offering his perspective, Sureshbabu Chigurupalli opines that in the era of data-driven insights, test and measurement instruments produce a wealth of valuable information. Advanced software and hardware carefully collect and store this data, while innovative analysis tools and machine learning algorithms uncover hidden relationships and trends. “With data seamlessly shared and monitored in real-time through cloud-based platforms, teams collaborate more effectively and make informed decisions with ease. Actionable reports and visualisations bring data to life, enabling predictive maintenance, automation, and unparalleled efficiency. In this data-rich landscape, innovation flourishes, product quality excels, and the future looks brighter than ever,” he explains.

 

“At Endress+Hauser, we understand that the true value of test and measurement instruments lies not just in the data they generate, but in how effectively that data is managed and utilised,” says Hemal Desai, and proceeds to share the points across which the company empowers customers to harness the power of their instrument data:

 

Seamless Data Acquisition and Integration: The instruments are designed for efficient data acquisition. Many offer digital communication protocols like HART®, Modbus®, or Profibus® for seamless integration with data acquisition systems (DAS) and Programmable Logic Controllers (PLCs). E+H also provides user-friendly software tools that simplify data collection and transfer from individual instruments or entire measurement networks.

 

Smart Data Management Solutions: E+H offers a suite of data management solutions like Netilion. This cloud-based platform provides secure storage for instrument data, allowing for easy access, visualisation, and analysis from any location. The data management solutions offer features like data filtering, aggregation, and real-time dashboards, empowering users to gain valuable insights from their measurement data.

 

Data collected from instruments can be used for various purposes, including:

• Process Optimisation: By analysing trends and identifying deviations, users can optimise process parameters for efficiency, quality control, and reduced waste.

• Predictive Maintenance: Continuous data analysis can help predict potential equipment failures, allowing for preventive maintenance and minimising downtime.

• Improved Product Quality: Real-time data insights can be used to ensure consistent product quality and identify areas for improvement within production processes.

 

Advanced Data Analytics and Services: E+H offers advanced data analytics services to help customers unlock the full potential of their instrument data. Our experts can assist with data interpretation, developing customi reports, and creating data-driven strategies for process improvement.

 

Security and Compliance: E+H prioritises data security and ensures compliance with relevant data privacy regulations. Our data management solutions offer robust security features like user authentication and access control.

 

“By providing a comprehensive suite of data acquisition, management, and analytics solutions, Endress+Hauser empowers our customers to transform raw data into actionable insights. We believe that leveraging the power of data is key to optimising processes, improving decision-making, and achieving sustainable success in today's industrial landscape,” explains Desai.

 

“Test and measurement instruments, such as mass flow meters and controllers, play a crucial role in data management and utilisation through advanced predictive maintenance and diagnostic functions. These devices are equipped with data logging capabilities that track a variety of parameters including flow rate, temperature, pressure, and valve status. By continuously recording and analysing this data, mass flow meters and controllers can predict the health status of the instruments and the overall condition of the processes they monitor,” says Wout van 't Wel. Per him, predictive maintenance is facilitated by identifying trends and patterns in the recorded data, allowing for the detection of potential issues before they lead to equipment failure. For instance, deviations from normal flow rates or unexpected temperature changes can signal impending problems. Additionally, multiple configurable alarms can be set to notify users of these anomalies in real-time, ensuring prompt action can be taken to mitigate risks and avoid downtime. “These advanced data management features not only enhance the reliability and efficiency of mass flow meters and controllers but also optimise the processes they control. By leveraging the collected data, users can make informed decisions, improve process control, and ensure the longevity of their instruments, ultimately leading to cost savings and increased operational efficiency,” Wout elaborates.

 

How can aspiring engineers and technologists prepare for a career in test and measurement?

 

According to Vilas Kulkarni, aspiring engineers and technologists can prepare for a career in test and measurement by focusing on a combination of formal education, practical experience, and continuous learning. He mentions some key steps to help prepare for a successful career in this field:

1. Educational foundation

2. Hands-on experience

3. Skills development

4. Certification and training

5. Staying updated with industry trends, and

6. Networking and professional associations.

 

“Careers in test and measurement can be built by building a strong educational foundation, gaining hands-on experience, developing both technical and soft skills, obtaining relevant certifications, staying updated with industry trends, and actively participating in professional associations. These steps will help ensure a well-rounded preparation and enhance prospects in the dynamic and evolving field of test and measurement,” says Kulkarni. 

 

Gaurav Bawa believes obtaining a relevant degree or certification in the career of your choice can help the aspiring engineers to grow their career. It is also recommended to develop skills in software and programming languages as well as stay updated with the industry trends. This would help you to stay ahead of your competitors and deliver the results as required. “The concept of success can be defined as the realisation of ambition with the help of hard work. Your career is not just a job, it is the story of your dreams, hard work, and resilience and the highest standards that you bring to work every day,” he advises.

 

For Darshana Thakkar, preparing for a career in test and measurement as an aspiring engineer or technologist involves developing a solid foundation in relevant technical skills, gaining practical experience, and staying updated with industry trends and standards. “In our education system, the curriculum changes after a few years. However, in recent times, technological advances have become so fast that until students pass their engineering degrees and enter the industry, new technology and trends are available in the industry application,” she says, cautioning budding engineers to stay tuned with the latest industrial advancements. To cope with this, universities are making industrial internships mandatory for engineering students. But most students take it as a burden and do it virtually or get a certificate. They should make active efforts to learn current advancements in their respective area. “Apart from the internship, learning from industry people, reading industrial magazines, and networking with industry people in various business forms provide continuous learning opportunities. Students must explore all the areas instead of sticking to their university curriculum,” she concludes.

 

Note: The responses of various experts featured in this story are their personal views and not necessarily of the companies or organisations they represent. The full interviews are hosted online at https://www.iedcommunications.com/interviews)