www.hpmag.co.uk HYDRAULICS & PNEUMATICS March 2026 39 improving performance. The analogue front end (AFE) is the first stage of the sensor interface, directly processing the sensor’s analogue output with ultra-low-noise amplifiers, precision filters, programmable gain stages and temperature circuits. In an ASIC, all these elements can be specifically designed and customised to match the unique characteristics of each sensor type and its operating environment. Furthermore, embedding these components directly on-chip enables early-stage signal conditioning, which minimises noise and distortion at the source. This is crucial in industrial environments rife with electromagnetic interference, mechanical vibration and subject to temperature variations. Integrating a high-resolution analogueto-digital converter (ADC) on the same ASIC further enhances performance by enabling immediate, precise digitisation of the conditioned analogue signals. This close integration reduces signal latency, eliminates the need for separate ADC hardware and cuts power consumption by minimising signal paths and redundant chip overhead. These improvements also conserve valuable board space, a crucial consideration for sensors embedded in compact or hard-to-access locations. Following digitisation, communication interfaces integrated within the ASIC facilitate seamless data transfer using protocols specifically suited to industrial automation. Protocols such as Serial Peripheral Interface (SPI) and InterIntegrated Circuit (I2C) offer robust, lowlatency wired communication, while wireless standards like Long Range (LoRa) and Bluetooth Low Energy (BLE) provide energy-efficient, long-range connectivity options. These tailored communication solutions ensure the reliable, real-time transmission of sensor data to controllers or cloud platforms, enabling vital applications such as predictive maintenance and process optimisation. Understanding the benefits The benefits of this integrated process become especially clear when looking at smart factory systems. For example, predictive maintenance sensors embedded in rotating machinery can use ASICs to deliver clean, highfidelity vibration data, even in the presence of harsh electrical noise, thereby enabling early fault detection and reducing costly downtime. Similarly, robotic systems demand fast and accurate sensor feedback. ASICs facilitate lowlatency signal processing and communication within a compact form factor, ensuring precise real-time control even in tight or vibration-prone environments. Meanwhile, environmental monitoring sensors within manufacturing plants benefit from the energy efficiency of ASIC integration, allowing them to operate on limited power budgets for extended periods, which reduces maintenance frequency and supports wireless deployment. As manufacturers accelerate toward smarter, more connected factories, success starts with reliable, high-quality sensor data. Custom ASICs make this possible by integrating the core functions required for accurate data capture and delivery into a single, robust chip designed for modern industrial demands. * Ross Turnbull is Director of Business Development at application specific integrated circuit (ASIC) expert Swindon Silicon Systems For further information please visit: https://www.swindonsilicon.com/ APPOINTMENTS NEXT EXIT Find your next Fluid Power Professional with the Hydraulics & Pneumatics Job Board & Appointments Page Harness the power Contact: Sales Manager – Andrew Jell 01732 370347 – andrew.jell@dfamedia.co.uk
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