Driving developments in embedded electronics

~ Custom ICs for compact, accurate sensing ~

Embedded systems are at the heart of many electronic devices we interact with day-to-day. But what’s next for the sector? Here, Ross Turnbull, Director of Business Development and Product Engineering at ASIC design and supply company Swindon Silicon Systems, explains how custom ICs can help overcome embedded system challenges.

Embedded systems offer manufacturers a variety of benefits, including compact size, low power consumption and application tailored performance. These benefits have made embedded systems desirable in various fast-growing industries, including IoT, automotive electronics and industrial automation.

System challenges

Despite the rising demand for embedded systems, the technology still faces challenges. First, safety. The increasing switch to electric vehicles, has caused the demand for more sophisticated automotive electronics to surge. Features such as adaptive cruise control, pedestrian recognition and collision sensors require complex embedded systems to provide the sensing and feedback capabilities needed for such demanding tasks.

But in the unlikely event the sensor system has an issue, the consequences are potentially serious. Therefore, ensuring that the embedded sensor offers the functionality required by its specific application is vital. And there must be no loss of performance or reliability —these systems must function correctly every time.

Security is another concern, particularly with IoT devices. In a manufacturing plant, IoT allows data to be collected across multiple equipment and machines. This data can be used to improve resource management, boosting productivity and overall process efficiency. However, this data may be targeted for cyberattacks. Therefore, system designers must also consider how best to protect the system right from the design stage.

Meeting safety, stability and security requirements — all while maintaining a minimal package size and low power consumption — can be challenging for system engineers. So, what’s the solution? To find it, we’ll need to explore embedded systems on a deeper level.

Enhancing performance

Processing units within embedded systems will typically be commercial-off-the-shelf solutions (COTS) such as Field Programmable Gate Arrays (FPGAs). This approach, however, is more suitable for manufacturers producing low and medium volumes.

Manufacturers working to much higher volumes or applications with extremely specific demands require a different approach. While an FPGA can be reprogrammed for different tasks, this flexibility often compromises performance, which isn’t safe or viable, in some applications.

Instead, manufacturers can opt for a fully customised device such as an Application Specific IC (ASIC). An ASIC is a bespoke chip designed for a specific task. It’s design specification means it delivers all the benefits of a COTS solution and optimises performance, improves sensor sensitivity and reduces power consumption. Consequently, it’s an ideal solution for manufacturers looking to secure a technical and commercial edge over their competitors.

Rather than re-engineering existing designs to fit around COTS devices or making sacrifices to achieve required performance levels, an ASIC can be fully optimised for its designated tasks. Moreover, developing an IC design alongside the embedded system can facilitate smoother integration, removing the need for costly redesigns.

Communication protocols, including BLE, I/O-Link, SPI and I²C are all available for integration onto the ASIC device. To alleviate security concerns, encryption processes or fully custom protocols can also be integrated onto the IC.

ASIC design begins at the lowest level, meaning only necessary circuits are included. This helps achieve a more compact package and PCB size and a more streamlined and robust board design, which is advantageous for industrial and transport applications, where heavy machinery and vehicles often create strong vibrations and movement.

For embedded system engineers, the custom IC design route offers significant advantages. As markets demand better and more sophisticated embedded technologies, ASICs will surely play a key role in its future.