Sensor Technology

A sensor chip is a special microchip that measures certain physical or chemical properties of the environment and converts the data into electronic signals that can be read and processed. RFID chips can integrate the sensor functions, the electronics required for signal processing, and the electronics required for RFID transmission on a single silicon chip, making them particularly efficient, compact, and cost-effective. Assemblies consisting of a separate sensor chip and an RFID chip with a digital or analog interface for capturing and subsequently transmitting sensor data are also possible.

In addition to RFID sensors, the most important sensor chips include LPWAN sensors, BLE sensors, NFC sensors, and WLAN sensors. Their ability to capture and transmit precise data makes a significant contribution to increasing efficiency and improving numerous processes. The different sensor types – LPWAN, BLE, NFC, and WLAN – each offer specific advantages and are used in different applications.

LPWAN sensors, which stand for Low Power Wide Area Networks, are particularly suitable for applications where a long range and low energy consumption are required. They are often used in industrial monitoring and agriculture. LPWAN sensors can be used in smart cities to monitor environmental parameters such as air quality, temperature, and humidity, for example. The long range of these sensors means that data can also be collected in remote areas, which is particularly beneficial in precision agriculture. Here, soil moisture sensors can help to optimize water consumption and increase crop yields. Another area of application is logistics, where LPWAN sensors are used to monitor supply chains and track goods.

Bluetooth LE sensors, i.e. Bluetooth Low Energy sensors, are characterized by their low energy consumption and their ability to communicate directly with mobile devices. These sensors are often used in health monitoring, for example in fitness trackers and wearable health devices, to measure vital signs such as heart rate and step count. BLE sensors are also used in building automation to enable light, temperature, and motion control. In retail environments, BLE beacons can be used to provide customers with personalized offers and information as soon as they enter the vicinity of certain products.

NFC sensors offer a very short range, which makes them ideal for secure and contactless applications. These sensors are often used in payment systems as they allow transactions to be carried out quickly and securely. NFC sensors are also used in access control systems, where users use their NFC-enabled cards or smartphones to open doors, or gain access to secure areas. In product tracking, NFC tags can be attached to packaging to verify the authenticity of products and prevent counterfeiting.

WLAN sensors use existing Wi-Fi infrastructures to transmit data, and therefore, offer high bandwidth and good integration into existing networks. These sensors are used in many smart home devices, from smart thermostats to security cameras that can stream video footage in real time. In industrial applications, WLAN sensors are used to monitor machine conditions and enable preventive maintenance measures. They also play an important role in the Internet of Things (IoT) by enabling connectivity and communication between different IoT devices and platforms.

Sensor chips measure physical parameters such as temperature, pressure, humidity, movement, light intensity, and more. There are also sensor chips that can detect chemical compositions, such as gas concentrations in the air. These often use special chemically reactive materials on the chip that react to changes in their environment.

The integration of sensors not only enables an RFID sensor system to recognize and track the identity of an object, but also to capture its condition and environmental data. The measured values generated by the sensors are collected and processed by the RFID tags, which are equipped with specific signal processing electronics. This data can then be retrieved by RFID readers and forwarded to higher-level systems for further analysis and processing.

In addition to data acquisition, sensor chips often also contain components for processing this data, such as analog-to-digital converters, which convert the analog signals recorded by the sensor into digital form. Microcontrollers can also be integrated, which process or pre-filter the data before it is sent to a higher-level system.

Communication: Modern sensor chips can also be equipped with wireless communication functionalities such as Bluetooth, NFC technology, or even WiFi, making them ideal for IoT applications.

RFID inlays, which are a supporting function for solutions with RFID, typically consist of an RFID chip, an antenna, and a substrate as the carrier material. The integration of a sensor into this arrangement expands the capabilities of the RFID tag, as it can also capture environmental data in addition to identification. This is referred to as an RFID sensor tag.

Which sensor is best suited to the respective application and the parameters to be measured must be decided before production. The sensor must be small, energy-efficient, and compatible with the RFID components.

The design of the RFID inlay must be adapted to accommodate the additional sensor and any additional cabling or circuitry. This may require a redesign of the component arrangement, the antenna, or even the chipset to avoid interference and ensure optimum performance.

In the case of a separate sensor, the sensor is physically integrated into the inlay, either by mounting it directly on the substrate next to the RFID chip or by embedding it in the substrate if the sensor is very small. This integration must be done precisely to avoid damage, and to ensure that the sensor can communicate correctly with the RFID chip. The electrical connection between the sensor, RFID chip, and antenna is crucial. As a rule, the sensor must be connected to the chip to enable data transmission. This can be done using fine conductive tracks or flexible printed circuit boards that are part of the inlay.

Once the sensor has been integrated, the modified RFID inlay must be extensively tested to ensure that both the RFID functionalities and the sensor data are correctly captured and transmitted. This includes function and range tests under various environmental conditions.

The finished RFID tag with the sensor may need to be specially packaged or protected to protect it from environmental influences that could damage the sensor or the RFID components. This is particularly important for sensors that are sensitive to moisture, pressure, or chemical influences, but sometimes also requires an opening in the tag to allow the environmental influences to act on the sensor.

In RFID systems, sensor technology plays a crucial role in expanding the functionality of the technology, and adapting it to specific application requirements. RFID sensors are a combination of RFID technology and sensors that make it possible, not only to identify objects, but also to capture status or environmental data. Here are some examples of sensors that can be integrated into RFID systems.

• Temperature sensors (temperature probes) are often built into RFID tags to monitor the temperature of transported goods, which is particularly important for the food and pharmaceutical industries to ensure compliance with cold chains.
• Moisture sensors are useful in the digitalization of agriculture and the digitalization of the construction industry where moisture levels can have a critical impact on product quality or material integrity.
• Pressure sensors can be integrated into RFID tags to measure pressure changes. This is used in the digitalization of the automotive industry and for monitoring packaged products.
• Vibration sensors are used in the monitoring of machines and vehicles to detect premature wear or potential defects.
• Light sensors can be integrated into RFID systems to determine whether an object has been exposed to light or not, which is important in the security industry or when monitoring the light exposure of certain products.
• Chemical sensors can be used for specialized applications, such as monitoring environmental conditions or controlling chemicals. RFID tags can be equipped with sensors that detect specific chemical changes.
• Acceleration sensors measure the acceleration in one or more axes. A sudden increase in acceleration followed by an abrupt stop can indicate that an object has fallen and suffered an impact (fall detection).
• Rotational movement sensors (gyroscope) measure the rotational movement around the axis of an object. In combination with acceleration sensors, they help to detect complex movement patterns, including falls.
• Sound sensors can capture noise and register deviations.
• Camshaft sensors work together with the crankshaft sensor. They measure and monitor the exact position of the crankshaft drive so that the engine control unit in the combustion engine recognizes when the first cylinder is at top dead center. Top dead center is the point at which the piston has reached the highest position in its cylinder before it is moved downwards again.

• Sensor devices with Bluetooth Low Energy (BLE) are ideal for wearables, health monitoring and smart home applications.
• Radio Frequency Identification (RFID) can be equipped with sensors, such as temperature or humidity sensors, to enable the monitoring of environmental conditions together with object identification. As the components are usually batteryless, the environmental parameters can only be measured when the RFID reader is powered.
• Sensor chips with mioty are used in industrial automation and smart or digital city projects.
• Sensor chips connected to a Low Power Wide Area Network (LPWAN) are ideal for applications that require a long communication range and long battery life, such as the monitoring of supply lines or agricultural areas.
• Wireless Local Area Network (WLAN IoT)-enabled sensor chips are widely used in smart home systems, medical devices, and office automation systems.

A combination of advanced systems and devices are increasingly being used to enable the independent operation of vehicles and machines. This is made possible, for example with autonomous technology and sensors. Further growth is expected.

According to the business intelligent platform “Statista”, the transportation segment holds the highest share of the global market for autonomous technology and sensors at 47.29 percent in 2022. This is followed by the manufacturing industry at 30.96 percent, the security industry at 4.64 percent, and the retail industry at 4.02 percent.

The global market for IoT sensors is also growing. According to market data platform “World Metrics”, the industrial sector has the highest application of IoT sensors at over 24 percent in 2020. In 2019, the pressure sensors segment within the IoT sensor market held the largest market share. Over 21.5 million IoT sensors were shipped globally in 2019.

Sensor technology, combined with the Internet of Things (IoT), has transformed various sectors, including retail, healthcare, and smart cities.

In retail, RFID and NFC sensors enable real-time inventory tracking and temperature monitoring to ensure quality control across the supply chain. In healthcare, wearable sensors and smart implants facilitate continuous patient monitoring, and IoT-enabled equipment tracking ensures efficient asset management. Environmental sensors maintain optimal conditions in hospitals. Sensor technology, combined with AI and robotics can also be used for automated replenishment in the hospital. In smart cities, sensor technology manages infrastructure through smart grids and water systems, and improves traffic flow with traffic sensors and smart parking solutions. Public safety is optimized by integrated surveillance systems and disaster management sensors, while environmental monitoring with air and noise pollution sensors enhances urban living.

Combining sensors with IoT technologies through cloud platforms, AI, and edge computing allows for seamless data integration, predictive analytics, and real-time decision-making, creating more efficient, safe, and responsive systems across these sectors.

The integration of sensor and processing functions on one chip saves space and improves performance by reducing the number of external components required. Sensor chips are often optimized to operate at very low power consumption, making them ideal for battery-powered or self-powered systems. In addition, the mass production of sensor chips using standardized semiconductor technologies is relatively inexpensive, even with advanced specifications. As miniaturization continues and semiconductor technology improves, sensor chips are becoming more powerful and versatile, enabling their use in an increasingly wide range of products and applications.

In real-time monitoring and control, RFID sensor systems make it possible to monitor the physical and chemical condition of objects. This is particularly important in sectors such as the pharmaceutical industry and in the context of digitalization in healthcare, where compliance with specific measurement parameters is crucial for product quality.

In the digitalization of industry and in industrial automation, sensor data improves automated decisions based on precise data. This can significantly increase the efficiency of production and supply chain processes. Sensor systems increase safety and reliability by continuously monitoring processes. Potential problems are thus detected earlier and preventive measures such as condition monitoring and predictive maintenance can be initiated. Downtimes are thus minimized. The precise monitoring and control of all operating processes also leads to energy savings, as all resources are used optimally. This is an advantage that leads to an increase in the sustainability of companies.

Overall, RFID sensor systems enable a more in-depth data collection and utilization that goes far beyond the conventional positioning and identification function of conventional RFID systems.

There is significant importance of sensor technology in the modern business landscape, especially in the context of the Internet of Things (IoT) and Industry 4.0. Sensors are the eyes and ears of intelligent systems and play a crucial role by providing the necessary data that companies need to effectively deploy advanced AI algorithms and machine learning. These technologies make it possible to gain valuable insights from the collected data that help to optimize operations, improve product quality and increase efficiency.

By integrating this sensory data into digital twins, companies can create digital images of their physical plants and processes. These digital twins make it possible to test different scenarios and strategies in a risk-free virtual environment before implementing them in the real world. In addition, the seamless integration of sensor technology and robotics supports the automation of complex and repeatable tasks, which not only increases productivity but also helps to minimize human error.

The ongoing digitalization of companies, which is being driven by the use of sensor technology, also promotes the sustainability of companies. Through a more precise monitoring and control of resources, companies can reduce their energy consumption and minimize their environmental impact. At a time when sustainable practices are becoming increasingly important, the efficient use of sensor technology offers a key technology to achieve environmental goals while securing economic benefits. As a result, sensor technology is becoming an indispensable part of modern companies that want to operate in an increasingly networked and digitalized environment.

The importance of sensor technology for all sectors of the economy is also driving the innovative development of sensors and sensor chips. These trends in sensor technology are opening up new opportunities for innovation in almost all branches of industry. The future of sensor technology promises even closer integration with artificial intelligence, a further improvement in energy efficiency, and increasing miniaturization, which is pushing the boundaries of what is technologically feasible.

• Miniaturization
  Sensors are becoming smaller and smaller, which facilitates their integration into a wide range of devices, from portable devices to embedded systems in infrastructure. This miniaturization significantly expands the application possibilities of sensors.
• Energy Efficiency
  The trend is moving towards increasingly energy-efficient sensors that enable the development of battery-powered or energy-autonomous systems. This is particularly important for IoT devices that are often used in remote or inaccessible locations.
• Multi-Sensor Integration (Sensor Fusion)
  The combination of different sensor types in a single device enables the collection of more complex and accurate data. This integration leads to better analysis and more precise results, e.g. in smartphones or vehicles.
• Intelligent Sensors
  With the advent of artificial intelligence and machine learning, sensors are being used not only to collect data, but also to process and analyze data directly at the point of collection. These sensors can recognize patterns, make decisions, and react proactively to their environment.
• Flexible and Stretchable Electronics
  Sensors based on flexible substrates can be applied to various surfaces or integrated into clothing and medical devices. This flexibility opens up new possibilities in medical technology and wearable technologies.
• Quantum Sensors
  These offer extremely high accuracy and sensitivity, and can detect the smallest changes in magnetic fields, gravity, light, and other physical quantities. They are used in areas such as geology, navigation, and medicine.
• Environmental Sensors
  With increasing concern about environmental problems, there is a growing demand for sensors to monitor air and water quality, soil conditions, and other environmental parameters. These sensors help to monitor and manage environmental problems. Sustainability is an increasingly important area of responsibility for companies.
• IoT and Networked Sensors
  In the Internet of Things, sensors are networked on a large scale to transmit data in real time, and to enable comprehensive monitoring and control systems.