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SENSORS


INDUSTRY ICS In a smart sensor, whether it is an ASIC or a standard IC, the chips ultimately perform the same function, but differ in terms of optimised performance. As the fundamental building block of smart sensors, the ICs perform the crucial signal conditioning and digital signal processing functions that converts, manipulates and processes analogue signals into a usable level and format for factory automation, along with the wired or wireless communications protocols. The specific applications depend on the type of sensor used, but there are several possibilities. In smart factories, every machine and process is a potential source of data that can be monitored to gain actionable insight. Using smart sensors to collect and analyse data, and to then make decisions based upon it, allows manufacturers to boost their facility’s productivity, extend system and machine lifespan and save energy. For example, for those looking for a solution to manage energy consumption, occupancy sensors can be used turn HVAC and lighting systems on and off when a space is occupied. The energy consumption of every machine on the factory floor can also be analysed in real time to identify any anomalous consumption that is indicative of faulty equipment. Then, facilities can deploy a repair engineer in a timely manner to prevent long lasting inefficiencies that affect overall facility performance. In some circumstances when production volumes are very low and the design is not intended to deliver exceptional performance, a selection of commercial off-the-shelf (COTS) components could offer sufficient performance credentials. However, in most cases it is more favourable to opt for an ASIC, which provides customised performance into a single compact package for a more optimised solution.


SPECIFIC OVER STANDARD The overarching benefit of ASICs is that they are designed to meet the product’s performance specification exactly - providing competitive technical and commercial advantages. While some may feel hesitant about the initial cost of a designing an ASIC, in the long term the cost benefits are substantial. By integrating as much of the circuitry as possible and engineering a


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bespoke specification, an ASIC provides a lower the bill of materials (BoM) and ease of manufacture, by reducing the component list. This is then coupled with the optimised performance that eliminates the use of over-specified off the shelf parts.


The other concern around


COTS components surrounds obsolescence, as they inevitably go obsolete when the manufacturer develops a new offering or if the sales volume drops below the threshold at which manufacturing the IC is financially profitable. But this isn't the case with ASICs. ASICs are designed with the non- obsolescence of both the silicon process and packaging in mind. In the rare chance of either becoming obsolete it is usually very easy to find alternative packaging. When it comes to silicon processes, it is important to work with a trusted partner. An ASIC supplier normally receives two years’ notice on silicon process obsolescence, providing ample time for a suitable solution to be implemented. ASIC design companies such as Swindon will usually guarantee that the device will be available until the customer halts its production by using methods such as storing wafers in dry nitrogen cupboards for up to 25 years.


The final area where ASICs offer benefits for Industry 4.0 applications is in intellectual property (IP) protection. With ASICs, it is extremely difficult to re-engineer an IC or reuse its IP in other designs. Swindon provides all its customers with full ownership of the completed system design ensuring that the IP of the final solution remains firmly in the customer’s possession. Swindon does not sell standard parts on the open market, thus ensuring that its customers’ IP will not be inadvertently used in a future related product. While COTS ICs may fulfil some of the essential performance requirements for Industry 4.0’s smart sensor applications, opting for an ASIC is a more dynamic investment providing differentiation from the competitors. An ASIC’s long-term cost savings, non- obsolescence and unmatchable IP protection separates the good smart sensor deployments that use off- the-shelf solutions from the great.


Swindon Silicon www.swindonsilicon.com


CAPACITIVE DISPLACEMENT MEASURING SYSTEM WITHSTANDS AMBIENT TEMPERATURES UP TO 800°C


The capaNCDT HT (High Temperature) measuring system is ideal for high precision distance, position, gap and thickness measurements in extreme ambient temperatures. The CSEx-HT sensors can be used in challenging ambient temperatures from -50°C to +800°C.


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The capaNCDT HT consists of a capacitive displacement sensor with integrated coaxial cable and a controller. Due to its high temperature stability and exceptionally high linearity throughout its operating temperature range, the capaNCDT HT delivers high precision measurements under harsh environmental conditions. Four sensor variants are available to choose from, which cover measuring ranges from 1mm up to 20mm. The sensors are sufficiently robust to withstand extreme temperature conditions while providing the best possible temperature stability. The integrated 1m cable (with drain wire acting as a ground) is extremely resistant to interference, which minimises signal interference caused by external electric or magnetic fields, for safe and trouble-free operation. Connection to the control electronics is made by use of an extension cable of either 1.4m or 2m length. The high-temperature sensors can be operated with the new high-performance capaNCDT 6228 controllers. A choice of two controllers is available. The DT6228 and DT6238 controllers both offer modular functionality allowing up to four sensor channels to be connected, with the DT6238 offering additional capability for EtherCAT communication and synchronisation of several 4-channel systems. The sensor system is calibrated at the factory before delivery. Applications for the capaNCDT HT range from rail and automotive, where it can be used for disc thickness variation and gap measurements, to the glass industry, where gap or distance measurements can be made in the coating process or in the production of float glass, as well as the steel industry, where gaps or strain can be measured inline during the production process. The capaNCDT HT is modular and is easily expandable with up to four additional measuring channels.


Micro-Epsilon www.micro-epsilon.co.uk


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icro-Epsilon has introduced a high temperature non-contact capacitive displacement measuring system to its already extensive capaNCDT range.


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