Sensor Development and Challenges

Sensors serve as vital sources of information about the state of a mechatronic system and its surroundings. This data is utilized to execute designated tasks, adapt system properties to changing environments, or enhance action precision.

Sensors play a pivotal role not only in mechatronics but also in various other sectors. They’re now extensively integrated into industrial products and systems, yielding improvements in performance across numerous applications:

• Consumer electronics
• Household products
• Public transport and automotive
• Process industries
• Manufacturing and production
• Agriculture and breeding
• Medical instruments
• And many more

The global sensor market is experiencing significant growth, offering over 100,000 different sensor types. This diversity underscores the wide-ranging sensor applications and the challenge of selecting the right sensor for specific needs. Factors contributing to the growing interest in sensors include:

• Reduced Prices: Sensor prices vary based on technology and production volume. Costs can range from several thousand euros for single units to a few euro cents for high-volume production.
• Miniaturization: Advancements in integrated circuit (IC) technology and micromachining enable sensor miniaturization. Silicon-based pressure sensors were among the early applications (1960s). Micro-ElectroMechanical Systems (MEMS) are gradually replacing traditional mechanical sensors. Solid-state sensors, compatible with silicon technology, are available for various measurements.
• Smart Sensing: Modern technology facilitates the integration of signal processing and sensing functions on a single chip. Specialized technology enables the processing of both analog and digital signals, leading to sensor modules with digital outputs that are bus compatible. This advancement is particularly relevant for mixed-signal applications.

The adoption of sensors continues to revolutionize industries and applications, driven by cost reductions, miniaturization, and the integration of smart sensing technologies.

MEMS (Micro-Electro-Mechanical Systems) sensors, such as accelerometers and gyroscopes, have gained popularity. MEMS accelerometers can be constructed entirely from silicon using micromachining technology. These accelerometers consist of a seismic mass connected to the substrate by flexible beams that act as springs. The movement of the mass can be detected using methods like integrated piezoresistors or capacitive techniques.

Mechatronics frequently involves sensors for measuring mechanical quantities. Common sensors include those for displacement (position) and force (pressure), but various other types also find applications in mechatronic systems.

While many commercially available sensors can be integrated into mechatronic systems, this approach suits simpler tasks and well-defined environments, such as industrial applications. However, for more complex tasks and specialized applications, dedicated sensor systems are often necessary. These may require special designs, further development, or research to meet specific requirements like dimensions, weight, temperature range, and radiation resistance.