• • • SAFETY IN ENGINEERING • • •
Overcoming the extreme How custom ASICs enhance sensor performance in extreme environments
cience fiction novelist, Arthur C. Clarke once said: “Any sufficient advanced technology is indistinguishable from magic.” In industries like oil and gas, aerospace and industrial automation, advanced sensor technology is making the impossible possible, enabling operations in environments once considered unreachable. Here Ross Turnbull, Director of Business Development and Product Engineering at ASIC design and supply specialist Swindon Silicon Systems, explains how Application Specific Integrated Circuits (ASICs) enhance sensor performance in extreme environments. From the depths of the ocean to the vacuum of space, modern industry relies on technology that can endure the harshest conditions on Earth and beyond. Sectors such as oil and gas, aerospace and industrial automation depend on sensor technology to maintain safety, precision, efficiency and performance in increasingly extreme environments.
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Ensuring safety and precision In environments where failure could lead to catastrophic outcomes, sensors are essential. They deliver critical data for predictive maintenance, real-time decision-making and system optimisation. By monitoring factors such as temperature, pressure, strain and vibration, sensors help prevent system failures that could jeopardise safety, productivity and the well-being of both people and the environment. For instance, in the oil and gas industry, downhole sensors allow for real-time monitoring of temperature, pressure and fluid composition at depths where temperatures can exceed 200 degrees Celsius, and where pressures may surpass 20,000 pounds per square inch (psi). These sensors enable real-time data acquisition, helping engineers detect anomalies such as transient pressure spikes; early indicators of
potential well blowouts. To function reliably, the associated signal processing electronics must endure high thermal stress, electrical noise and mechanical shock.
In aerospace, flight sensors monitor altitude, velocity and structural integrity to reduce the risk of catastrophic failures during flight. These sensors must also endure intense vibrations, rapid accelerations and extreme temperature fluctuations. Similarly, in high-speed, high-pressure manufacturing environments, sensors embedded in robotic systems regulate temperature, monitor mechanical stress and maintain precise control. This monitoring helps reduce manufacturing defects and optimise production efficiency. Ensuring reliable sensor performance in these harsh environments requires robust integrated circuits (ICs) designed for precision signal acquisition, noise immunity and extended operational lifetimes. Application-Specific Integrated Circuits (ASICs) are increasingly critical in this domain, offering tailored solutions optimised for extreme thermal, mechanical and electromagnetic conditions. Unlike general- purpose ICs, ASICs provide custom-designed architectures that enhance sensor accuracy, minimise power consumption and integrate advanced fault-tolerance mechanisms.
Advancing sensor performance with custom ASICs
ASICs are custom-designed chips tailored to meet the unique demands of specific applications. Unlike standard ICs, which are designed for general-purpose use, they provide significant advantages when it comes to handling complex sensor data in extreme environments. In environments with high electromagnetic
interference (EMI) or radio frequency interference (RFI), such as aerospace or oil and gas, ASICs
employ advanced analogue-to-digital (ADC) and digital-to-analogue (DAC) converters, along with noise filtering techniques and active noise cancellation systems. These design features work together to reduce electrical noise, ensuring that the ASICs maintain high signal integrity and accurate sensor data, even in the presence of external interference. Temperature resilience is another critical factor.
Silicon-on-Insulator (SOI) and Silicon Carbide (SiC) materials are commonly used in ASIC designs to enable them to withstand extreme thermal conditions. SOI technology enhances thermal stability, allowing ASICs to function reliably at temperatures up to 300 degrees Celsius, while SiC- based ASICs are capable of operating at even higher temperatures, up to 600 degrees Celsius. To further optimise performance in high- temperature environments, ASICs can incorporate thermal management solutions such as micro- channel cooling systems and heat sinks, which actively dissipate heat and prevent thermal damage. Furthermore, temperature compensation circuits can be integrated directly into the ASICs, adjusting sensor outputs to ensure accurate readings even in rapidly fluctuating or extreme thermal conditions.
In environments where power is limited, ASICs can be designed for energy efficiency, helping to extend sensor lifespans. By incorporating low- power analogue and digital circuitry, ASICs reduce overall energy consumption. Additional features, such as sleep modes, dynamic power scaling and the ability to power down inactive components, further minimise power usage and enhance the operational lifespan of sensors. For particularly power-constrained applications, energy-harvesting technologies, such as solar, thermoelectric or vibration-based generators, can be integrated into the ASIC, enabling sensors to operate autonomously for long periods without the need for frequent battery replacements. These technologies are especially valuable in applications like deep-sea exploration, remote monitoring in space and other areas where traditional power sources are scarce or difficult to maintain. Swindon offers a full turnkey solution that supports the design and optimisation of ASICs for extreme environments. This comprehensive approach, which spans from initial concept through to manufacturing and testing, ensures that each solution is tailored to meet the specific performance and reliability of demanding applications, allowing for seamless integration into industries with unique environmental challenges. Custom ASICs are turning what was once thought to be impossible into reality. As industries continue to push the boundaries of what’s possible in extreme environments, these advanced chips are advancing sensor performance. With the help of ASIC technology, industries can now operate in some of the harshest conditions on Earth and in space, turning complex challenges into opportunities for innovation.
32 ELECTRICAL ENGINEERING • MAY 2025
electricalengineeringmagazine.co.uk
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