Turning sensor signals into actionable industrial data

SENSORS ARE the eyes and ears of modern industrial systems, converting physical phenomena such as temperature, pressure, motion or strain into electrical signals. However, these raw outputs are rarely ready for action, leaving control systems vulnerable to errors. 

According to Siemens’ 2025 thought-leadership insight, ‘Smart manufacturing: The future of digital factories’, sensors are reshaping manufacturing, allowing “the seamless flow of data between machines, devices and systems, facilitating real-time monitoring, analysis and autonomous decision-making”. 

Achieving this level of operational insight relies on every sensor delivering accurate, stable and consistent measurements in real time. However, the initial output from a sensor, also known as the raw sensor signal, is often weak, noisy and highly susceptible to environmental and electrical interference. 

Why raw sensor signals fall short​

A raw sensor signal represents the measured parameter at its most fundamental level. At this stage, the signal is extremely vulnerable. 

Many industrial sensors generate signals with amplitudes of only a few millivolts, leaving very little tolerance for interference. In busy industrial settings, electrical noise from motors, switching power supplies, inverters and high-frequency drives can easily couple into these small signals, distorting them. When sensors are located far from the control cabinet, long cable runs add further vulnerability by picking up common-mode noise or creating ground loops, both of which can shift or obscure the true measurement before it reaches the electronics that process it. 

To overcome these challenges, raw sensor outputs must be amplified, filtered and corrected before they can be reliably used by industrial control and monitoring systems. 

While many of these conditioning functions can be implemented using discrete components, a sensor interface ASIC integrates amplification, filtering, compensation digitisation and diagnostics into a single, optimised chip. This ensures every stage of the signal chain is tightly controlled, consistent and tailored to the specific sensor technology. 

Transforming signals 

A sensor interface ASIC takes vulnerable, variable raw signals and converts them into stable, accurate and application-ready outputs. 

The process begins with precision amplification, in which low-noise input stages amplify very small sensor signals without altering their shape. These circuits also help block interference from surrounding equipment, ensuring that the signal entering the system is as clean as possible. Built-in filtering then removes high-frequency electrical noise and smooths sudden disturbances. This helps the measurement reflect what the sensor is detecting, rather than the activity surrounding it. 

To address issues such as temperature drift, nonlinearity and small variations between individual sensors, ASICs include on-chip calibration and compensation. These functions adjust the signal's gain, offset and linearity, helping the measurement remain accurate under changing conditions and throughout the sensor's lifetime. 

Once stabilised, the analogue signal is converted into a reliable digital output using high-resolution analogue-to-digital converters (ADCs) designed for the specific sensor type. Digitising the signal early reduces its vulnerability to electrical interference and enables it to connect easily to programmable logic controllers (PLCs), microcontrollers and industrial networks. 

A foundation for predictive maintenance

As well as conditioning the signal, ASICs also provide built-in diagnostics, such as detecting open or short circuits, over-temperature conditions or signals that fall outside expected ranges. These features support predictive maintenance and help improve system safety. 

Furthermore, with all functions integrated on a single silicon platform, long-term performance becomes far more consistent. Component drift is minimised, printed circuit board (PCB) complexity is reduced and every sensor benefits from the same tightly controlled calibration routines. The result is a cleaner, more reliable and longer-lasting signal chain than is achievable with discrete components alone. 

Reliable sensor data is the foundation of modern industrial facilities. Sensor interface ASICs provide manufacturers with the confidence to act on real-time data, supporting smarter decisions, greater efficiency and more resilient systems. 

Ross Turnbull is director of business development at Swindon Silicon Systems

For more information:

www.swindonsilicon.com

Tel: +44 (0)1793 649400