
Sensor Development
Custom Sensor Development Services for Industrial Automation & Robotics
We design precise and robust industrial automation sensors for our clients worldwide, ensuring product quality, increasing efficiency and trouble-free performance. We provide a full range of services to create customised sensor systems with pre-configured software tailored to your business needs, from hardware to certification.
Our sensor systems can be used for environmental monitoring, motion tracking, pressure monitoring and many other tasks. By connecting sensors and its data to the cloud, combined with sophisticated software and analytics, our clients identify trends, optimise production processes and accurately detect potential problems with their machines.
Sensor Development: What We Design
Temperature & Humidity Sensors
Custom temperature sensors are available in various forms, including thermocouples, resistance temperature detectors (RTDs), thermistors, etc. It can be used in hazardous areas and withstand extreme temperatures, pressures, and vibrations.Â
The humidity sensor design is essential in industries where precise control of humidity levels is required, and these sensors also offer real-time monitoring and reporting under challenging conditions.
Vendors
Hilscher, Analog Devices, Texas Instruments, NXP, Microchip, STMicroelectronics, Renesas, Melexis, Maxim Integrated
Platforms
ARM Cortex M0/M0+/M1, ARM Cortex M3/M4/M7, ARM Cortex M23/M33/M35P, RISC-V, Hilscher NetX SoC, DSP
Types
Thermocouple (E, J, K, M, N, T, B, S, R, Platinum/rhodium-alloy, C, D, G), resistance temperature detectors (RTDs) Pt100, Pt1000
Libraries
X-CUBE-MEMS1
Solutions
Pyrometers, thermographic camera (infrared camera, thermal imaging camera, thermal camera, thermal imager), acoustic temperature sensors, smart wired (Wireless) temperature sensors
Networks
Ethernet APL, RS-485, Modbus RTU, CANOpen, IO-Link, HART, PROFIBUS, 4-20 mA (Current loop), 0-20 mA, 0-10 V, single-pair Ethernet (SPE)
Flow Sensors
Flow sensors are used in various industries, including oil and gas, chemical and water treatment. These sensors provide information on the flow rate of liquids or gases, enabling operators to optimise processes, detect leaks and reduce energy consumption. Our team offers flow sensor design based on the turbine, ultrasonic and magnetic systems. Each has unique advantages, but they all provide accurate fluid flow measurements.
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Networks
Ethernet APL, RS-485, Modbus RTU, CANOpen, IO-Link, HART, 4-20 mA (Current loop), 0-20 mA, 0-10 V, single-pair Ethernet (SPE), PROFINET RT/IRT, PROFIBUS
→ More about our designs for industrial networks
Solutions
Ultrasonic flowmeters, mass flowmeters (Coriolis), electromagnetic flowmeters, differential pressure flowmeters, vortex flowmeters, mechatronic flowmeters, thermal flow switches
Vendors
Hilscher, Analog Devices, Texas Instruments, NXP, Microchip, STMicroelectronics, Renesas, Maxim Integrated
Libraries
MSP-USSSWLIB_Water, FlowMeter, TI USSSWLib for ultrasonic sensing
Platforms
ARM Cortex M0/M0+/M1, ARM Cortex M3/M4/M7, ARM Cortex M23/M33/M35P, RISC-V, Hilscher NetX SoC, DSP, FPGA
Pressure Measurements
Pressure measurement sensors are used to measure and monitor the pressure in various industrial processes using fluid, pneumatic, and hydraulic systems. We design custom pressure sensors to meet the specific needs of our clients and ensure high accuracy, reliability, and durability.Â
The sensor design depends on the type of pressure being measured and the environmental conditions in which the device will be used. Sensors that are designed to measure low pressures may not be suitable for high-pressure applications and vice versa.
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Vendors
Hilscher, Analog Devices, Texas Instruments, NXP, Microchip, STMicroelectronics, Renesas, Maxim Integrated
Platforms
ARM Cortex M0/M0+/M1, ARM Cortex M3/M4/M7, ARM Cortex M23/M33/M35P, RISC-V, Hilscher NetX SoC, DSP
Networks
Ethernet APL, RS-485, Modbus RTU, CANOpen, IO-Link, HART, 4-20 mA (Current loop), 0-20 mA, 0-10 V, single-pair Ethernet (SPE), PROFINET RT/IRT, PROFIBUS
→ More about our designs for industrial networks
Solutions
Sensors with digital display for industrial applications, pressure sensors for hazardous areas, sensors with display for sanitary applications, sensors for high temperature with integrated triclamp for sanitary applications, pressure sensors with two switching outputs, sensors with display for pneumatic applications
Level Sensing
Level sensor design plays a significant role in industrial automation, enabling the creation of sensors with higher resolution, wider measurement ranges, and greater environmental resilience. Such sensors measure and control the level of various liquids and solids in tanks, silos, and other containers. There are different types of level sensors: ultrasonic, capacitive, radar, and float sensors.
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Vendors
Hilscher, Analog Devices, Texas Instruments, NXP, Microchip, STMicroelectronics, Renesas, Maxim Integrated
Networks
Ethernet APL, RS-485, Modbus RTU, CANOpen, IO-Link, HART, 4-20 mA (Current loop), 0-20 mA, 0-10 V, single-pair Ethernet (SPE), PROFINET RT/IRT, PROFIBUS
→ More about our designs for industrial networks
Platforms
ARM Cortex M0/M0+/M1, ARM Cortex M3/M4/M7, ARM Cortex M23/M33/M35P, RISC-V, Hilscher NetX SoC, DSP
Libraries
TI USSSWLib for ultrasound sensing
Solutions
Capacitive non-contact level measurement, guided wave radar probes, guided wave radar probes for sanitary applications, residue suppression level switches for hazardous areas, point level sensors for industrial applications, residue suppression level switches for sanitary applications, capacitive probes with integrated temperature, sensors with capacitive technology, non-contact level measurement, the non-contact level measurement for hygienic applications
Position Sensors
Position sensors in industrial automation are used to measure the position of various mechanical components such as actuators, valves, and robotic arms. Some of the common types of position sensors include linear variable differential transformers (LVDTs), rotary encoders, and magnetic sensors.Â
- LVDTs are commonly used to measure the position of linearly moving components, such as hydraulic or pneumatic actuators.
- Rotary encoders measure the rotational position of components, such as motors or robotic arms.
- Magnetic sensors use a magnetic field to detect the position of moving parts and are often used in harsh or high-temperature environments.
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Vendors
Analog Devices, Texas Instruments, NXP, Microchip, STMicroelectronics, Lattice Semiconductor, AMD (Xilinx), Intel FPGA
Networks
EtherCAT, RS-485, RS-422, Modbus RTU, SSI, BISS, EnDat, ABZ (HTL/TTL), ABZ (Sin/Cos), HIPERFACE DSL, DeviceNet, PROFINET RT/IRT
→ More about our designs for industrial networks
Platforms
FPGA, CPLD, ARM Cortex M0/M0+/M1, ARM Cortex M3/M4/M7, ARM Cortex M23/M33/M35P, RISC-V, DSP
Libraries
X-CUBE-MEMS1
Solutions
Absolute encoders, incremental encoders
Gas Detectors
Gas detectors in industrial automation are used to detect and monitor hazardous gases in the workplace. These detectors help maintain workers' safety and prevent accidents. Gas sensors development is becoming increasingly important as regulations become stricter and the consequences of accidents become more severe.Â
There are several types of gas detectors:Â
- Infrared sensors use infrared light to detect the presence of gases. Electrochemical sensors use a chemical reaction.
- Catalytic sensors use a heated wire to detect the presence of combustible gases.
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Vendors
Hilscher, Figaro, Draeger, Winsen, Gastec, Analog Devices, Texas Instruments, NXP, Microchip, STMicroelectronics, Renesas, Maxim Integrated
Networks
Ethernet APL, RS-485, Modbus RTU, CANOpen, IO-Link, HART, 4-20 mA (Current loop), 0-20 mA, 0-10 V, single-pair Ethernet (SPE), PROFINET RT/IRT, PROFIBUS
→ More about our designs for industrial networks
Platforms
ARM Cortex M0/M0+/M1, ARM Cortex M3/M4/M7, ARM Cortex M23/M33/M35P, RISC-V, Hilscher NetX SoC, DSP
Lidars & Radars
Lidar and radar sensors are used to detect and measure the distance to objects in a given environment. They are essential in various applications, including robotics, autonomous vehicles, and industrial machinery, where accurate navigation is critical. Thanks to its benefits, production increased accuracy, improved efficiency, enhanced safety, and reduced downtime.
- Lidar sensors (light detection and ranging) use lasers to create a high-resolution 3D map of the environment, enabling precise detection and measurement of objects.
- Radar sensors use radio waves to detect objects and measure their distance, velocity, and direction of movement.
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Vendors
Analog Devices, Texas Instruments, NXP, Microchip, STMicroelectronics, Renesas, Maxim Integrated, Infeneon, Silicon Radar, Acconeer, HI-Link
Radiation Sensors
Radiation sensors in industrial automation are used to detect and measure ionising radiation in the workplace. It helps improve safety in compliance with regulations, reduce the risk of radiation exposure and lower insurance premiums.
Several types of radiation sensors include Geiger-Muller (GM) tubes, scintillation detectors, and semiconductor detectors.
- GM tubes are commonly used for detecting gamma and beta radiation and are ideal for portable applications.
- Scintillation detectors use a crystal material to detect gamma and neutron radiation.
- Semiconductor detectors are used for alpha, beta, and gamma radiation detection.
The choice of radiation sensor depends on the specific industrial application, the type of radiation being detected, the required sensitivity, and the environmental conditions in which the sensor will be used.
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Vendors
Hilscher, Analog Devices, Texas Instruments, NXP, Microchip, STMicroelectronics, Renesas, Maxim Integrated, LND, IDEAS, Hamamatsu, CERN Medipix
Networks
Ethernet APL, RS-485, Modbus RTU, CANOpen, IO-Link, HART, 4-20 mA (Current loop), 0-20 mA, 0-10 V, single-pair Ethernet (SPE), PROFINET RT/IRT, PROFIBUS
→ More about our designs for industrial networks
Platforms
ARM Cortex M0/M0+/M1, ARM Cortex M3/M4/M7, ARM Cortex M23/M33/M35P, RISC-V, Hilscher NetX SoC, DSP
Substance Sensors
In industrial automation, substance sensors are used to detect and measure the properties of various substances. There are different types of substance sensors:
- Optical sensors use light to detect substances. Electrochemical sensors use chemical reactions to measure the properties of substances.
- Gas sensors detect and measure the presence of gases in the environment.
Substance sensors are widely used in various fields, including manufacturing, chemical processing, and environmental monitoring, to monitor the quality of materials and ensure that products, chemical reactions, air, water, and soil meet the required standards.
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Vendors
Hilscher, Analog Devices, Hamilton, Hamamatsu, Texas Instruments, NXP, Microchip, STMicroelectronics, Renesas, Maxim Integrated
Networks
Ethernet APL, RS-485, Modbus RTU/ASCII/TCP, CANOpen, IO-Link, HART, 4-20 mA (Current loop), 0-20 mA, 0-10 V, single-pair Ethernet (SPE), PROFINET RT/IRT, PROFIBUS
→ More about our designs for industrial networks
Platforms
ARM Cortex M0/M0+/M1, ARM Cortex M3/M4/M7, ARM Cortex M23/M33/M35P, RISC-V, Hilscher NetX SoC, DSP
Vision & Imaging Sensors
Vision and imaging sensors enable machines to "see" and interpret visual information. They are essential for inspection, quality control, and robotic guidance. Common types of sensors include CCD (charge-coupled device) cameras, CMOS (complementary metal-oxide-semiconductor) cameras, and thermal imaging cameras.Â
- CCD cameras are used for high-resolution imaging applications and are ideal for low-light environments.
- CMOS cameras are more affordable than CCD cameras for a wide range of imaging applications.
- Thermal imaging cameras use infrared radiation to detect object temperature differences and are helpful for industrial applications such as predictive maintenance and process control.
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Vendors
AMD (Xilinx), Intel FPGA, NVIDIA
Camera Interface
CameraLink HS, CXP12, CXP6, CameraLink Deca, 5 GigE, USB3, CameraLink Base, 1 GigE, MIPI CSI-2
Application Examples
Reading 1D|2D codes, text recognition (OCR), position/rotation detection, checking for presence and completeness, fill level monitoring, printing and labelling inspection
Functions pt.1
– pattern matching, contour detection, brightness detection, greyscale value threshold and contrast detection, flexible 360° position tracking, calliper tool for measuring tasks, blob analysis;
– 2D codes: ECC200, QR-Code, PDF 417;
– evaluating the quality of the code, Multi-code reading, Reading directly marked codes, OCR;
Functions pt.2
– 1D barcodes: EAN, UPC, RSS, 2/5 interleaved, 2/5 industrial, code 39, code 93, code 128, GS1, pharmacode, codabar;
– colour area: determines the colour area or a colour range;
– colour list: compares a colour with a list of known colours to sort parts accordingly;
Functions pt.3
– colour value: determines average colour values RGB/HSV/LAB for output via interfaces;
– object sensor functions such as pattern comparison, contour recognition, calibration, etc.;
– code reader functions such as barcodes, data matrix and plain text reading.
Electric Meters & Power Network Analysers
Electric metres and power network analysers measure and monitor electrical parameters such as voltage, current, power, energy, and power quality in electrical systems.Â
There are several types of electric metres and power network analysers, including digital metres, analogue metres, smart metres, and portable analysers. Digital and smart metres can communicate with other devices, collect data, and provide real-time information about energy consumption and power quality.
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Vendors
Analog Devices, Texas Instruments, NXP, Microchip, STMicroelectronics, Renesas
Networks
IEC 61850, IEC 60870-5-101, IEC 60870-5-102, IEC 60870-5-103, IEC 60870-5-104 | Power Line Communication: PLC/PLC G3/G3-PLC Hybrid, IEC 62056 (DLMS/COSEM), DLMS/COSEM over LoRaWAN, DNP3, ION, Modbus RTU/ASCII/TP
Hardware
PLC (power line communication)
– STMicroelectronics: ST8500, STCOM, ST7580
– Texas Instruments: AFE031
– Renesas: R9A06G061, R9A06G037
HSR/PRP
– Texas Instruments: AM335x, AM437x, AM57x, AMIC110, AMIC120
– FPGA: AMD (Xilinx), Intel (Altera), Lattice, GOWIN
– Microchip Technology: KSZ9477, LAN9371, LAN9372, LAN9373
– Arrow Electronics: Flexibilis XRS7003E, Flexibilis XRS7004E
Energy Metering ICs
– STMicroelectronics: STPM32, STPMS2, STPM01, STPM1X, STPM33, STPM34, STPMC1
– Analog Devices: ADE9430, ADE7979, ADE9322B, ADE9153A, ADE9153B, ADE9000, ADE9078, ADE7923, ADE7932, ADE7933, ADE7978, ADE7854A, ADE7858A, ADE7868A, ADE7878A, ADE7816, ADE7880, ADE7953, ADE7757A, ADE7751, ADE7755
Algorithms
Active power and energy wideband, active power and energy fundamental, reactive power and energy, apparent power and energy from RMS data, apparent power vectorial calculation, RMS, period, zero-crossing (zero-crossing detection), combined voltage zero-crossing, phase-delay, sag and swell, tamper, digital front end (DFE), phase compensation, decimation, filters, calibration, PQ, angle measurement











Our Services
We are ready to guide you through every step of your automation journey – from proof of concept to mass production.


Why Promwad

Cost-Effective Approach
We allocate an engineering team with a tech lead & management to work together with our client’s teams. Therefore, our clients do not have to bring in their own in-house specialists or an expensive external integrator.

EtherCAT Group Member
As a member of the EtherCAT Group, we follow all the established industry standards. Our customers can access the necessary data at any time and can improve the efficiency of their machines and equipment.

Turnkey Product Development
At Promwad, you can to cover all the bases of turn-key product design with a single contractor. Also, you can use our cross-industry expertise in the IIoT, telecom, adaptive computing, and automotive industries.
Our Cooperation Models
Flexible approach to suit your current needs

Dedicated Team
We will form a team to fit your specific engineering task. You are free to manage it and provide additional resources.

Project-Based
We can join you at any stage or take on the entire project, including our management and risk control.

Fixed Price Model
This contract fixes the price so that it does not depend on resources used or time expended by our engineering team.

Time and Material
A T&M contract is the best option for your flexible set of tasks that are difficult or impossible to fix and assess in advance.
Our Case Studies in Industrial Automation
Do you need a quote for custom sensor development for industrial automation & robotics?
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