PLANT MACHINERY & SITE SAFETY
monoxide, as well as airborne particulates like welding fumes and silica dust. These sensors provide continuous feedback, allowing operators to respond immediately to changes in atmospheric conditions – often before the threat becomes visible or measurable through other means.
Proximity and thermal sensors support more responsive machine behaviour. When a worker enters a restricted zone or a machine component begins to overheat, these sensors can trigger alarms or implement emergency stops to prevent injury. In this way, safety becomes proactive rather than reactive, reducing reliance on human intervention in fast-moving or high-risk situations.
Sensor data also underpins predictive maintenance strategies. By tracking performance indicators such as vibration and temperature, sensors can help identify early signs of equipment failure. This enables maintenance teams to act before a fault leads to a dangerous incident and causes injury, while simultaneously preventing downtime and damage to equipment.
“BY TRACKING PERFORMANCE INDICATORS SUCH AS VIBRATION AND TEMPERATURE, SENSORS CAN HELP IDENTIFY EARLY SIGNS OF EQUIPMENT FAILURE.”
Sensors are also essential to robotic systems that operate in environments too hazardous for human workers. For example, Light Detection and Ranging (LiDAR) sensors enable robots to generate high-resolution, 3D maps of their surroundings, allowing them to navigate complex environments with minimal human input. However, if LiDAR sensors lack sufficient resolution, refresh rate or resistance to environmental interference like dust or steam, robots struggle with accurately perceiving their surroundings – increasing the risk of collision or system failure.
To prevent issues such as this, it’s crucial that sensor components can maintain accurate and reliable performance, even in challenging factory conditions.
ELEVATING SENSOR SYSTEMS At the core of most sensor-based systems is an integrated circuit (IC), enabling accurate signal processing and communication with other system components. While off-the-shelf components are suitable for some standard applications, they can prove limiting in safety-critical environments where precision, responsiveness and long- term reliability are a must.
To meet these requirements, a custom solution is preferable. Application-specific ICs (ASICs) are designed to meet the precise needs of each application, offering the high-performance signal processing and accuracy required for detecting minute changes in hazardous environments.
Mixed-signal ASICs, which combine analogue and digital processing on a single chip, are particularly well-suited to real-time monitoring. By reducing component count, they support faster response times and minimise points of failure. Additionally, because ASICs are developed for long-term use in a specific system, they offer greater protection against obsolescence compared to off-the- shelf chips.
Advanced sensing technology is indispensable for manufacturers seeking to minimise risk without compromising productivity. By integrating sensor-driven systems supported by custom ASICs, manufacturers can create intelligent and proactive safeguards that not only prevent accidents but also flag issues before they become hazards.
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