In industrial data acquisition, collecting data is only half the job. A well-designed alarm system turns data into immediate action, helping factories prevent downtime and costly equipment failures.
1. What Is an Industrial Alarm System?
An industrial alarm system continuously monitors sensor and machine data and triggers alerts when values exceed predefined thresholds.
Typical alarm triggers include:
- Over-temperature
- Over-pressure
- Abnormal vibration
- Power loss
- Communication failure
2. Why Alarms Are Critical
Without alarms, problems are often discovered too late.
Alarms enable:
- Early fault detection
- Faster response time
- Reduced unplanned downtime
- Improved equipment lifespan
This is especially important for unattended or remote sites.
3. Types of Industrial Alarms
1. Threshold Alarms
Triggered when a value crosses a fixed limit (e.g., temperature > 80°C).
2. Rate-of-Change Alarms
Detect sudden changes, even if limits are not exceeded.
3. Communication Alarms
Alert when sensors, PLCs, or gateways stop responding.
4. Logical Alarms
Triggered by conditions combining multiple signals (AND/OR rules).
4. Alarm Delivery Methods
Modern DAQ platforms can send alarms via:
- SMS
- Web notifications
- Mobile apps
- Integration with SCADA or ticket systems
Fast delivery ensures issues are handled immediately.
5. Best Practices for Alarm Design
- Avoid too many alarms (alarm fatigue)
- Set realistic thresholds
- Use priority levels (low / medium / high)
- Log all alarm events for analysis
A well-configured alarm system turns industrial data into a proactive maintenance tool.
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