Overcoming the extreme

10 April, 2025

Science fiction novelist, Arthur C. Clarke once said, “any sufficient advanced technology is indistinguishable from magic”. In industries like oil and gas, aerospace, and industrial automation, advanced sensor technology is making the impossible possible, enabling operations in environments once considered unreachable.

From the depths of the ocean to the vacuum of space, modern industry relies on technology that can endure the harshest conditions on Earth and beyond. Sectors such as oil and gas, aerospace and industrial automation depend on sensor technology to maintain safety, precision, efficiency and performance in increasingly extreme environments.

Ensuring safety and precision

In environments where failure could lead to catastrophic outcomes, sensors are essential. They deliver critical data for predictive maintenance, real-time decision-making and system optimisation. By monitoring factors such as temperature, pressure, strain and vibration, sensors help prevent system failures that could jeopardise safety, productivity and the well-being of both people and the environment.

For instance, in the oil and gas industry, downhole sensors allow for realtime monitoring of temperature, pressure and fluid composition at depths where temperatures can exceed 200 degrees Celsius, and where pressures may surpass 20,000 pounds per square inch (psi). These sensors enable real-time data acquisition, helping engineers detect anomalies such as transient pressure spikes — early indicators of potential well blowouts. To function reliably, the associated signal processing electronics must endure high thermal stress, electrical noise and mechanical shock.

In aerospace, flight sensors monitor altitude, velocity and structural integrity to reduce the risk of catastrophic failures during flight. These sensors must also endure intense vibrations, rapid accelerations and extreme temperature fluctuations.

Similarly, in high-speed, high-pressure manufacturing environments, sensors embedded in robotic systems regulate temperature, monitor mechanical stress and maintain precise control. This monitoring helps reduce manufacturing defects and optimise production efficiency.

Ensuring reliable sensor performance in these harsh environments requires robust integrated circuits (ICs) designed for precision signal acquisition, noise immunity and extended operational lifetimes. Application-Specific Integrated Circuits (ASICs) are increasingly critical in this domain, offering tailored solutions optimised for extreme thermal, mechanical and electromagnetic conditions. Unlike general-purpose ICs, ASICs provide custom-designed architectures that enhance sensor accuracy, minimise power consumption and integrate advanced fault-tolerance mechanisms.

Advancing sensor performance with custom ASICs

ASICs are custom-designed chips tailored to meet the unique demands of specific applications. Unlike standard ICs, which are designed for general-purpose use, they provide significant advantages when it comes to handling complex sensor data in extreme environments.

In environments with high electromagnetic interference (EMI) or radio frequency interference (RFI), such as aerospace or oil and gas, ASICs employ advanced analogue-to-digital (ADC) and digital-to-analogue (DAC) converters, along with noise filtering techniques and active noise cancellation systems. These design features work together to reduce electrical noise, ensuring that the ASICs maintain high signal integrity and accurate sensor data, even in the presence of external interference.