Predictive maintenance with RFID/NFC sensor transponders
05.11.2025
Oberhaching, November 2025
RFID/NFC sensor transponders are not only used for the contactless identification of objects, machines, materials and tools, but can also detect physical variables such as temperature, humidity, vibrations or pressure. RFID/NFC sensor transponders combine RFID/NFC technology with sensor technology and thus open up new possibilities for condition-based maintenance - so-called predictive maintenance.
Functional principle - simple and effective
RFID/NFC sensor transponders consist of three main components:
- Microchip - stores identification and sensor data
- Antenna - enables wireless communication with an RFID reader or mobile device
- Sensor - measures a physical quantity, e.g. temperature, humidity, vibration or pressure.
Classically, a passive RFID/NFC sensor solution is used in predictive maintenance. This means that the RFID/NFC sensor transponder does not require its own power supply - the energy is transferred inductively to the RFID/NFC sensor transponder via the electromagnetic field of the RFID/NFC reader. Expensive and inconvenient battery changes are no longer necessary. In addition, the sensors can also be used on components that are difficult to access or rotate - for example on a gearbox.
If, however, the sensor parameter is to be recorded and stored independently of a reader field, a separate energy source is required. Such systems are known as loggers. Their integrated batteries enable the RFID/NFC sensor transponder to "wake up" at set intervals, measure the sensor value and save it. The RFID/NFC sensor transponder then switches back to energy-saving mode.
Application example in the field of predictive maintenance
In the context of industrial gearboxes, parts, tools or machine components, an unnoticed increase in friction is often a harbinger of a fault - for example due to a lack of lubricant, bearing failure or wear. The resulting friction causes a rise in temperature in the housing, which can be detected at an early stage. This is where RFID/NFC sensor transponders from smart-TEC come into play.
Data analysis and early detection
Depending on the application, the RFID/NFC sensor transponder is attached directly to the gearbox housing. The RFID/NFC sensor transponder records the temperature continuously or at regular intervals. As soon as an external or housing temperature rise is registered, the RFID/NFC sensor transponder can transmit the data wirelessly to a reader or gateway and on to an internal maintenance system. By automatically analyzing the temperature values, a warning is triggered in the event of a significant increase - so that maintenance teams can take action at an early stage before critical damage or failure occurs.
Label or hard tag - both are possible!
Depending on the environmental conditions, the RFID/NFC sensor transponder can be packaged differently. Flexible labels with an integrated sensor chip are possible, as are robust, resistant RFID/NFC sensor transponders suitable for industrial use.
smart-SENSOR Temperature
In many industries, from the food industry to hospitals and care units, permanent and fully automatic temperature measurement is required. This can be done using either a thin, self-adhesive RFID/NFC label with an integrated sensor chip or a very robust, flexible RFID/NFC industrial transponder.
smart-SENSOR Humidity
Relative humidity measurement is used in greenhouses or on farms, for example. The humidity of medical textiles can also be monitored. Depending on requirements, thin, self-adhesive labels or robust industrial transponders can be used.
smart-SENSOR Temperature & Humidity
Temperature in combination with relative humidity can be measured using an RFID/NFC transponder. Depending on the application, you can opt for a thin, self-adhesive label, a robust industrial transponder or a digital metal nameplate.
Conclusion: RFID/NFC-based predictive maintenance offers numerous advantages
It enables contactless and maintenance-free measurement without a direct electrical connection and can even be used on moving components or components that are difficult to access. Continuous condition monitoring allows changes in operation to be detected at an early stage - without interrupting production. Seamless integration into existing IT systems enables automatic data analysis, allowing anomalies to be detected at an early stage, extending the service life of the systems and significantly reducing unplanned downtime.
