Sensors Development

Sensor Development

Custom Sensor Development for Industrial Automation & Robotics

We design precise industrial automation sensors for our clients worldwide, ensuring product quality, and trouble-free performance. Our team provides 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 other tasks. By integrating cloud-connected sensors and their data with advanced software and analytics tools, our clients streamline production, identify trends, and accurately identify machine issues.

Our Custom Sensor Design Services

Explore custom sensor design services at Promwad, where our engineers collaborate with you to develop sensor solutions compliant with the required industry standards and certifications, ensuring your seamless entry into the market.

Temperature & Humidity Sensors

Custom temperature sensors are available in various forms, including thermocouples, resistance temperature detectors (RTDs), thermistors, and more. 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. These solutions also offer real-time monitoring and reporting under challenging conditions.

With extensive experience in temperature and humidity sensor development, we design solutions optimised for your specific environment, measurement range, and required accuracy.

 

Vendors

Hilscher, Analog Devices, Texas Instruments, NXP, Microchip, STMicroelectronics, Renesas, Melexis, Maxim Integrated

Platforms

ARM Cortex M0/M0+/M1, M3/M4/M7, and 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; RTDs (resistance temperature detectors): Pt100, Pt1000

Libraries

X-CUBE-MEMS1

Solutions

Pyrometers, thermographic camera (infrared camera, thermal imaging camera, thermal camera, thermal imager), acoustic and 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 processing, and water treatment. These systems 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

Solutions

Ultrasonic, electromagnetic, differential pressure, vortex, and mechatronic flowmeters; mass flowmeters (e.g. Coriolis metres); 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, M3/M4/M7, and M23/M33/M35P; RISC-V, Hilscher NetX SoC, DSP, FPGA

Pressure Measurements

Pressure measurement sensors monitor and estimate the pressure in various industrial processes using fluid, pneumatic, and hydraulic systems. We design custom pressure transducers to ensure high accuracy, reliability, and durability. 

We consider two key factors to optimise the performance of your custom pressure sensors:

  1. The type of pressure that will be measured.
  2. The environmental conditions in which the devices 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, M3/M4/M7, and 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

Solutions

Sensor design with integrated digital display for industrial applications, pressure transducer solutions for hazardous areas, sensors with display for sanitary and pneumatic applications, sensors for high temperature with integrated tri-clamps for sanitary applications, pressure sensors with two switching outputs

Level Sensing

Level sensor design enables the creation of solutions with higher resolution, wider measurement ranges, and greater environmental resilience. Such systems control the level of various liquids and solids in tanks, silos, and other containers. Our level sensor development services include creating ultrasonic, capacitive, radar, and float solutions.

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

Platforms

ARM Cortex M0/M0+/M1, M3/M4/M7, and 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 for hygienic applications

Position Sensors

Position sensors measure the placement of various mechanical components such as actuators, valves, and robotic arms. The solutions include linear variable differential transformers (LVDTs), rotary encoders, and magnetic sensors. 

  1. LVDTs are commonly used to control the position of linearly moving components, such as hydraulic or pneumatic actuators.
  2. Rotary encoders monitor the rotational position of components, such as motors or robotic arms.
  3. Magnetic fields detect the position of moving parts 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

Platforms

FPGA, CPLD, ARM Cortex M0/M0+/M1, M3/M4/M7, and M23/M33/M35P; RISC-V, DSP

Libraries

X-CUBE-MEMS1

Solutions

Absolute and incremental encoders

Gas Detectors

Gas detectors detect hazardous gases in the workplace. These systems help maintain workers' safety and prevent accidents. Gas sensor 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 detectors use infrared light to detect the presence of gases.
  2. Electrochemical detectors use a chemical reaction.
  3. Catalytic detectors 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

Platforms

ARM Cortex M0/M0+/M1, M3/M4/M7, and M23/M33/M35P; RISC-V, Hilscher NetX SoC, DSP

Lidars & Radars

Lidar and radar sensors evaluate the distance to objects in a given environment. They are essential in various applications, including robotics, autonomous vehicles, and industrial machinery, where safety, accurate navigation, and reduced downtime are critical.

  1. Lidars (light detection and ranging) use lasers to create a high-resolution 3D map of the environment, enabling precise detection and measurement of objects.
  2. Radars use radio waves to detect objects and measure their distance, velocity, and direction of movement.

 

 

Vendors

Analog Devices, Texas Instruments, NXP, Microchip, STMicroelectronics, Renesas, Maxim Integrated, Infineon, Silicon Radar, Acconeer, HI-Link

Radiation Sensors

Radiation sensors measure ionising radiation in the workplace. It helps improve safety in compliance with regulations, reduce radiation exposure and lower insurance premiums.

Radiation sensors include scintillation and semiconductor detectors, and Geiger-Muller (GM) tubes.

  1. GM tubes detect 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.

When developing custom solutions for our clients, we consider the type of radiation being detected, the required sensitivity, and the environmental conditions.

 

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

Platforms

ARM Cortex M0/M0+/M1, M3/M4/M7, and M23/M33/M35P; RISC-V, Hilscher NetX SoC, DSP

Substance Sensors

We develop the following types of substance sensors:

  1. Optical solutions, using light to detect substances.
  2. Electrochemical solutions, utilising chemical reactions to measure the properties of substances.
  3. Gas solutions, detecting the presence of gases in the environment.

Substance sensors are widely used in various fields, including manufacturing, chemical processing, and environmental control, 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

Platforms

ARM Cortex M0/M0+/M1, M3/M4/M7, and M23/M33/M35P; RISC-V, Hilscher NetX SoC, DSP

Vision & Imaging Sensors

Vision and imaging sensors enable machines to recognise and interpret visual information. They are used in 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 in low-light environments.
  2. CMOS cameras are more affordable than CCD cameras and are employed in diverse imaging applications.
  3. Thermal imaging cameras utilise 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, availability and completeness check, fill level monitoring, printing and labelling inspection

Functions pt.1

– Pattern matching, contour detection, brightness detection, greyscale value threshold, contrast detection, flexible 360° position tracking, calliper tool for measuring tasks, blob analysis
2D codes: ECC200, QR-Code, PDF 417
– Code quality evaluation, multi-code reading, directly marked code reading, OCR

Functions pt.2

1D barcodes: EAN, UPC, RSS, 2/5 interleaved, 2/5 industrial, code 39, 93, and 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, including pattern comparison, contour recognition, and calibration
Code reader functions such as barcodes, data matrix and plain text reading

Electric Metres & Power Network Analysers

Electric metres and power network analysers measure and monitor electrical parameters such as voltage, current, energy consumption, and power quality in electrical systems. 

These solutions include portable analysers and digital, analogue, and smart metres. Digital and smart metres can communicate with other devices, collect data, and provide real-time information.

 

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 and fundamental reactive power and energy, apparent power and energy from RMS data, apparent power vectorial calculation, RMS, period, 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

Discover our proven expertise in custom sensor development for industrial automation & robotics.

Proven expertise in hardware and software development for industrial automation

Cost-effective approach

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

EtherCAT Group Member

EtherCAT Technology Group member

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

Turnkey product design

Turnkey product development

At Promwad, you can cover all the bases of turnkey product design with a single contractor. The tools we use in our sensor development services cater to various industries, including IIoT, telecom, adaptive computing, and automotive.

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 and 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.