Sensors Development

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. 

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.

 

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. 

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.

 

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.

 

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. 

  1. LVDTs are commonly used to measure the position of linearly moving components, such as hydraulic or pneumatic actuators.
  2. Rotary encoders measure the rotational position of components, such as motors or robotic arms.
  3. Magnetic sensors use a magnetic field to detect the position of moving parts and are often used in harsh or high-temperature environments.

 

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. 

There are several types of gas detectors: 

  1. Infrared sensors use infrared light to detect the presence of gases. Electrochemical sensors use a chemical reaction.
  2. Catalytic sensors use a heated wire to detect the presence of combustible gases.

 

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.

  1. 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.
  2. Radar sensors use radio waves to detect objects and measure their distance, velocity, and direction of movement.

 

Learn more in our case study

 

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.

  1. GM tubes are commonly used for detecting gamma and beta radiation and are ideal for portable applications.
  2. Scintillation detectors use a crystal material to detect gamma and neutron radiation.
  3. 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.

 

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:

  1. Optical sensors use light to detect substances.
  2. Electrochemical sensors use chemical reactions to measure the properties of substances.
  3. 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.

 

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. 

  1. CCD cameras are used for high-resolution imaging applications and are ideal for low-light environments.
  2. CMOS cameras are more affordable than CCD cameras for a wide range of imaging applications.
  3. Thermal imaging cameras use infrared radiation to detect object temperature differences and are helpful for industrial applications such as predictive maintenance and process control.

 

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. 

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.

 

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

Why Promwad

Proven expertise in hardware and software development for industrial automation

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

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 design

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.

Do you need a quote for custom sensor development for industrial automation & robotics?

Drop us a line about your project! We will contact you today or the next business day. All submitted information will be kept confidential.