ELECTRONIC SENSORS The Benefits of Bespoke
The global industrial sensors market was valued at USD 19.29 billion in 2019, and by 2027, it is expected to reach USD 33.56 billion. This growth is largely attributed to the swift adoption of industry 4.0, advancements in industrial sensor technology, and the need to remain compliant with ever-developing safety regulations.
A
long with this general growth in the sensors market, Barney Mitchell, Special Projects Group Manager at Solid State Supplies, has seen a rise in demand for custom-made sensors and systems. In this article, Barney explains the likely reasons for this, and how organisations across industries are benefiting from bespoke sensor systems.
Drive to being safer and more efficient
The uplift we’ve seen in recent years in demand for custom sensors is mainly due to the limitations of their off-the-shelf counterparts. Standard sensors are designed with generic applications in mind, but for many industries, especially those which are heavily regulated, that’s just not good enough. As technology in custom sensors advances and the ability to measure more varied and granular parameters develops, industries are empowered to be safer and more efficient. We’ve seen a concerted drive for customised sensors in sectors including healthcare, oil and gas, automotive, chemical, and automation and robotics.
Remaining compliant
These industries are closely monitored to ensure they remain compliant to stringent regulations. Relying on a standard sensor to detect an issue in a life-or-death situation could be inviting disaster if it does not precisely fit the parameters requiring monitoring.
We are specialists in designing and manufacturing sensors and systems for highly regulated industries. For the healthcare sector,
we provide optical, temperature and pressure sensors.
Medical applications frequently require sensors for fluid diagnostics. For example, a customer approached us needing a sensor to measure the volume of hazardous fluids filling a container. We designed an optical fill level sensor, which triggers a warning when the container reaches a certain level, alerting the supervisor to the situation. If there’s no intervention and the fluids reach critical levels, the sensor disables the system automatically, preventing hazardous waste from overflowing. One challenge facing users of optical sensors is variable ambient lighting conditions. Off-the-shelf sensors check for signal presence, but varying background conditions can trigger false readings. A finely tuned, customised sensor circuit will process data and discount noise accurately in these environments, enabling correct system function.
Responding to temperature changes
The electric vehicle (EV) market is another area where we’ve seen an increased demand for custom sensors. We’re currently working on a project to develop a temperature sensor assembly for stator windings. Sudden dramatic rises in temperature can be extremely dangerous in electric vehicles, where lithium battery packs are used.
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Sustainability requirements mean that EV manufacturers are seeking reusable sensors, which can be reattached after removal for motor servicing. Most off-the-shelf sensors must be discarded once removed and can’t be reused.
The oil and gas sector is also eager for bespoke sensors - one popular usage being overfill sensors on fuel trucks. It takes less than two minutes to fill a 5,000-litre fuel container. Overfilling can literally split a tanker in half, which of course, is extremely dangerous — and costly.
Our custom-made solution in this instance is an optical sensor circuit which fits into the top of the tanker compartment. It works by measuring the light reflecting off a prism. As the fluid levels rise, the optical path changes. Once the signal disappears, the sensor circuit detects the problem and immediately shuts off the operation.
Bringing a vision to life
It’s not just about creating a sensor system which performs the basic function. The real value of a specialist sensor solution designer is their ability to translate a customer’s concept into a robust, compliant product. Customers will often come to us with a vision. It’s our job to bring that vision to life.
Solid State Supplies
www.sssltd.com
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