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Table of Contents
Connector Manufacturers Connect to Sensors
Table of Contents
Chapter 1 Report Scope and Methodology

Survey Objectives ............................................................................................................................... 1-1
Issues addressed in this report .......................................................................................................... 1-1
Methodology and Approach .............................................................................................................. 1-3
Chapter 2 Executive Summary

Executive Summary ............................................................................................................................ 2-1
Connector Manufacturer Issues......................................................................................................... 2-3
Chapter 3 Introduction
Introduction ....................................................................................................................................... 3-1
General Sensor Types and Technologies ........................................................................................... 3-2
Chapter 4 Sensor Types and Technologies

Introduction ....................................................................................................................................... 4-1
Sensor Types………………………………………………………………………………………………. .................................. 4.2
Sensor Technologies .......................................................................................................................... 4-4
Micro Electromechanical Systems Sensors ...................................................................................... 4-10
Sensor Interconnect ......................................................................................................................... 4-15
Sensor Fusion ................................................................................................................................... 4-18
Chapter 5 Sensor Applications

Introduction ....................................................................................................................................... 5-1
Consumer Electronics………………………………………………………………………………………… ........................... 5-2
Internet of Things ............................................................................................................................... 5-6
Industrial Automation / Process Control ......................................................................................... 5-11
Commercial………………………………………………………………………….. ....................................................... 5-16
Automotive…………………………………………………………………………………………………………………………………5-23
Healthcare / Biomedical…………………………………………………………………………………………………………….. 5-31
Smartphones……………………………………………………………………………………………………………………………… 5-37
Military / Aerospace……………………………………………………………………………………………………………… ..... 5-40
Chapter 6 Sensor Industry Leaders

Introduction ....................................................................................................................................... 6-1
Large Sensor Industry Leaders……………………………………………………………………… ................................. 6-2
TOC-1
Robert Bosch GmbH / Bosch Sensortec………………………………………………………………………………………...6-3

Texas Instruments…………………………………………………………………………………………………………………………6-4
STMicroelectronics……………………………………………………………………………………………… ......................... 6-5
NXP Semiconductors N.V. .................................................................................................................. 6-6
Honeywell International.. .................................................................................................................. 6-7
Infineon Technologies AG…………………………………………………………………………………………………………… . 6-8
Sensor Manufacturers by Application Segment…………………………………………………………………………….6-9
Sensors a Global Industry………………………………………………………………………………………………………………6-10
Sensor Device Packagers……………………………………………………………………………………………………………….6-11
Chapter 7 Sensor Industry Standards

Introduction ....................................................................................................................................... 7-1
Related Industry Standards ................................................................................................................ 7-2
Development / Prototype Kits ........................................................................................................... 7-5
Chapter 8 Connector / Sensor Manufacturer Synergy

Introduction ....................................................................................................................................... 8-1
Amphenol Advanced Sensors ........................................................................................................... 8-6
Molex Sensor Solutions.................................................................................................................... 8-13
TE Connectivity Sensing Solutions ................................................................................................... 8-17
Additional Connector and Sensor Manufacturers ........................................................................... 8-25
AVX Corporation ...................................................................................................................... 8-25
Foxconn Interconnect Technology………..…………………………………………………… ......................... 8-25
Hirose……………………………………………………………………………………………………………………………….. . 8-25
JAE…………………………………………………………………………………………………………………………………… .. 8-26
Methode Electronics…………………………………………………………………………………………………………. . 8-26
Omron……………………………………………………………………………………………………………………………..... 8-27
Samtec………………………………………………………………………………………………………………………………..8-28
Sensata………………………………………………………………………………………………………………………………. 8-29
Vishay………………………………………………………………………………………………………………………………… 8-29
Yazaki………………………………………………………………………………………………………………………………….8-30
Chapter 9 Sensor and Application Trends

General Sensor Issues………………………………………………………………………………………………………………..... 9-1
Micro-Electromechanical Systems Issues .......................................................................................... 9-5
Internet of Things ............................................................................................................................... 9-6
Artificial Intelligence……………………………………………………………………………………………………………………..9-7
Sensors in Wearable and Medical Applications…………………………………………………………………………… . 9-9
Robotics…………………………………………………………………………………………………………………………………….. 9-12
TOC-2
Chapter 10 Sensor Market Values and Forecasts

Introduction………………………………………………………………………………………………………………………………….10-1
Total World Sensor Sales 2017 through 2023F…………………………………………………………………………….. 10-2
Total World Sensor Sales by Region, 2017, 2018 and 2023 with 5-year CAGR…………………...……….. 10-3
Total World Sensor Market by Region, Ranked by 5-year CAGR…………………………………………………… 10-3
Total World Sensor Sales by region, 2017 - 2023F with % change and 5-year CAGR………….………… 10-4
Total World Sensor Sales Percent Market Share by Region, 2017 through 2023F………………………….10-5
Total World Sensor Sales by Region, Percent Market share, 2017 through2023F…………………………. 10-5
2018F Sensor Sales, Percent market Share by Region…….……………………………………………………………. 10-6
2023 Sensor Sales, Percent Market Share by Region……………………………………………………………………..10-6
Total World Sensor Sales by Equipment Sector, 2017, 2018F with 5-year CAGR…...……………………. 10-7
Total World Sensor Market by Equipment Sector Ranked by 5-year CAGR, 2018F-2023F ............ 10-7
Total World Sensor Sales by Equipment Sector, 2017-2023F with Percent Change and 5-year
CAGR………………………………………………………………………………………………….................................. 10-8
Total World Sensor Sales % Market Share by Equipment Sector, 2017-2023F……………………………… 10-9
Total World Sensor Sales by Equipment Sector, % Market Share, 2017-2023F……...…………………….. 10-9
2018F Sensor Sales, Percent market Share by Equipment Sector……………...…………………………………. 10-10
2023 Sensor Sales, Percent Market Share by Equipment Sector….……………………………………………….. 10-10
Total World Sensor Sales by Technology, 2017, 2018F with 5-year CAGR...…………………………………..10-11
2018F Total World Sensor Sales by Technology….…………………………………………………………………………10-11
2023F Total World Sensor Sales by Technology….…………………………………………………….…………………..10-12
MEMS Sensor Technology Sales by Equipment Sector, 2017, 2018F with 5-year CAGR…….…………..10-12
2018F MEMS Sensor Technology Market Share by Equipment Sector……...………………………………… 10-13
2023 MEMS Sensor Technology Market Share by Equipment Sector……….…………………………………… 10-13
NEMS Sensor Technology Sales by Equipment Sector, 2017, 2018F and 2023F
with 5-year CAGR………………………………………………………………………………………………………………..10-14
2018F NEMS Sensor Technology Market Share by Equipment Sector……...……………………………………10-14
2023F NEMS Sensor Technology Market Share by Equipment Sector…………………………………………… 10-15
CMOS Sensor Technology Sales by Equipment Sector, 2017, 2018F, and 2023F
With 5-year CAGR………………………………………………………………………………………………………………. 10-15
2018F CMOS Sensor Technology Market Share by Equipment Sector……...……………………………………10-16
2023F CMOS Sensor Technology Market Share by Equipment Sector……...………………………………….. 10-16
Chapter 11 Major Findings and Conclusions

Introduction…………………………………………………………………………………………………………………………………. 11-1
Key Points……………………………………………………………………………………………………………………………………..11-1
TOC-3
Chapter 1
Chapter 1 Report Scope and Methodology

The scope of this report is the analysis of the rapidly growing market for electronic sensors and the
continuing addition of sensors offered by several traditional connector manufacturers. Sensors of all
types have played critical roles in medical, industrial and avionic applications for many years, but the
arrival of the Internet of Things, the evolution of factory automation, autonomous transportation along
with an ongoing explosion of advanced consumer products have created unprecedented growth
opportunities for sensing devices of all types.
Leading manufacturers of electronic connectors have spent years designing, tooling and marketing
literally thousands of connector types to satisfy the demands of product engineers resulting in the
challenge of managing tens of thousands of part numbers. As demands for lower cost drove connector
manufacturing to off-shore locations, the logistics of distribution continue to grow. At the same time,
commoditization of formal and de-facto standard interfaces such as Universal Serial Bus drive profit
margins to absolute minimums. Longer term threats to the traditional connector manufacturer business
model include the potential loss of design-in control as industry-driven standard system designs erode the
ability to influence connector selection. Additionally the prospect of select high-speed copper backplane
and input/output (I/O) interfaces eventually being replaced with fiber optic connectors may be seen as a
disruption to long-term future growth in the traditional connector segment.
As is common with most product manufactures, immediate as well as long-term sales growth is a mandate
built into the DNA of connector manufacturers. A rapidly expanding array of new applications and
performance requirements has traditionally provided the connector industry with plenty of opportunities
for sales growth. A potential limit to that business model may be stimulating a shift in product direction
in order to re-establish a clear long-term migration path to future growth. As a result sensors may be
playing a larger role in the product mix offered by select connector manufacturers.
The key objectives of this study are to explore critical issues associated with the technology of the
expanding array of electronic sensors, as well as the synergy between the manufacture of sensors and
electronic connectors.
Issues addressed in this report

1. What functions do sensors perform?
2. What technologies are used in electronic sensors?
3. What types of sensors are being used today?
4. What applications utilize sensors?
5. Which connector companies are currently expanding their sensor product mix?
6. Who are the current leaders in the electronic sensor industry?
7. What is driving the interest in sensors by connector manufacturers?
8. What advantages can connector manufacturers bring to the sensor market?
9. What is the synergy between the manufacturers connectors and sensors?
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10. Can connector manufacturers leverage their cable assembly capabilities to offer additional
value?
11. What are the challenges facing connector manufacturers that expand their sensor offerings?
12. What are the fastest growing applications for electronic sensors?
13. Are connector manufacturers focusing on commodity or more specialized sensor types such as
high-reliability / ruggedized sensors?
14. Can connector manufacturers utilize existing marketing and sales structures to sell sensors?
15. What is “sensor fusion”?
16. What specific sensor applications or market segments are most attractive to connector
manufacturers?
17. What new product applications are expected to offer the greatest growth potential over the
next five years?
18. How are connector manufactures expanding their sensor technology and manufacturing
resources?
19. Where are electronic sensors manufactured?
20. What is the global market value of electronic sensors?
21. What is the global market forecast for electronic sensors over the next five years?
The analysis of electronic sensors and their relationship with connectors is an entirely new venture for
Bishop & Associates, and required the creation of an internal statistical database as well as a through
technical understanding of the industry. The vast array of existing sensor types are continuing to evolve
as new applications require unique sensing capabilities in terms of accuracy, reliability, environmental
resistance, physical size and cost.
This report is a snapshot of the sensor industry as reviewed in Spring 2018, as well as how a select subset
of connector manufacturers are choosing to expand their participation in this product segment.
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Methodology and Approach
Our approach to this project included:
▪ Interviews with knowledgeable electronics industry personnel involved in the

design and development of products that utilize electronic sensors.
▪ Interviews with representatives of applicable industry standards organizations.
▪ Interviews with related market researchers and independent consultants familiar

with both the electronic connector and sensor markets.
▪ Collection and review of technical articles and advertising in industry trade

publications.
▪ Interviews with leading manufacturers of electronic connectors and sensors.
▪ Extensive Internet searches for related data.
▪ Utilization of the Bishop and Associates database of electronic connectors as well

as a new statistical database of electronic sensors.
In some cases non-disclosure agreements inhibited the inclusion of information involving new product
applications, product release schedules, and market forecast data. Every effort was made to verify the
accuracy of information presented in this report from multiple sources.
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Chapter 2
Chapter 2 Executive Summary

We live in a period of rapid change
where a new disruptive technology
can result in the total upheaval of
long- established markets and
suppliers. Removable computer
memory transitioned from 8” floppy
disks that contained kilobits of data
to flash drives that now feature
Terabits of capacity. Published for
over 100 years, the hardbound
World Book Encyclopedia has been
made obsolete by access to the
Internet. Starting in 1906, the Royal
Typewriter Company began manufacturing typewriters in Hartford, Connecticut but after many
restructurings, product changes and introduction of the personal computer, only one manual typewriter
manufactured in China is still in production. The ubiquitous smartphone has completely altered the
communication, photography, entertainment, social networking and advertising markets and plays a
central role in countless applications. Cloud computing has replaced purchased software with software
as a service on demand model forcing suppliers to adjust or become irrelevant. Amazon on-line sales
are threatening long-established brick and mortar retailers who were slow to recognize the impact the
Internet would have on their business model. Surviving and thriving in this new environment requires
constant review of current products for relevance as well as exploration of new business opportunities
that offer potential for long-term growth.
In some cases, companies that collect and distribute information are growing much faster than those
that manufacture physical products. Market value of traditional industry giants such as IBM, General
Electric, AT&T, and Xerox have been surpassed with fast growing leaders such as Apple Computer,
Google, Facebook, and Amazon. A characteristic of these new leaders is their flexibility that allows them
to pursue business opportunities that may be entirely outside of their core business. They have grown
logarithmically to the point that companies such as Facebook have begun upsetting traditional design
and procurement practices by designing open standard computing equipment they use in their immense
data centers. Clearly, the ability to rapidly recognize, adjust, and pursue new business opportunities
that may offer accelerated sales growth has become a critical survival skill, especially when the current
product mix begins to exhibit long-term limitations. Both large and small companies are searching for
new business growth opportunities in order to avoid obsolescence in slow growing or stagnant markets.
This is especially true where products have become commodity items with limited profitability.
Electronic sensors have existed in many forms for years. They provide critical input in control and
management systems that range from the distillation of crude oil to the temperature in our homes.
Sensors are the link between conditions in the physical world and electronic equipment that utilizes the
resulting data to monitor and/or take appropriate action. A variety of sensing technologies including
optical, piezoelectric, thermal expansion, magnetic, capacitance, ultrasonics, infrared detection, gravity
detection, and GPS location are now incorporated in medical, industrial control, avionic, as well as
consumer products.
2 -1
The average smartphone typically utilizes at least eight sensors, with many more that can be attached
for special applications. Given the fact that we may be in the early stages of transition to a fully
electronic future, sensors represent incredible volume growth potential, especially in selected niche
markets where accuracy, reliability, and durability in harsh environments is an absolute requirement.
The average automobile currently represents one of the largest volume and fastest growing applications
for electronic sensors. The typical car today utilizes sensors that manage everything from the
combustion cycle of the engine to the desired interior temperature. Dozens of other sensors manage
transmission shifting as well as stand ready to trigger an air bag if a collision is detected. Newer cars
that feature driver assist functions add many more sensors, while full autonomous cars will require a
new class of internal and external sensors that must operate with extreme reliability in a wide variety of
challenging environments.
We are only at the opening chapter of changes that the Internet of Things (IoT) will bring. Sensors will
play expanding roles in the home (smart home), office, on public thoroughfares as well as in the
Industrial Internet of Things (IIoT). This fact has not been lost on several manufacturers of connectors.
Manufacturers of electronic connectors participate in a over $60 billion annual global business that has
thrived over the past 75 years as electronics have replaced mechanical systems and have become an
integral element in the universe of modern devices we enjoy today. Each generation of electronic
device has offered improved performance, features, reduced size, and often at a lower cost. Literally
thousands of connector types have been designed and sold to satisfy the performance and size required
by next generation products. The vast majority of these connectors have been designed for termination
to copper conductors. Fiber optic connectors have continued a path to improved bandwidth,
ruggedness, and termination process, but the cost of the electro-optic conversion process continued to
limit use of optical links to longer channels where copper losses would be unacceptable. Recent
advances in materials and silicon photonics may be changing that assumption.
The integrity of high-speed signals conducted in copper wire is corrupted by crosstalk, attenuation,
skew, and electromagnetic interference which only gets worse as the length of the channel increases.
Current copper interfaces have taken advantage of advanced signal conditioning technology in order to
extend their datarate as well as practical reach. The rise of PAM4 signaling has alleviated some of the
negative characteristics of non return to zero signaling (NRZ) to achieve 56+ Gb/s channels, but it may
be only a temporary reprieve. Continuing demand for higher bandwidth and signal density may soon
reach the practical limits of traditional copper connectors. The long-predicted transition from copper
based interfaces to fiber optic may finally be in sight. The result may be the practical limitation of high-
speed copper interfaces, potentially limiting future growth.
The manufacture of fiber optic connectors requires extreme precision molding and assembly, but they
are typically much smaller and lighter than their copper equivalents. Optical signals are immune to
external EMI, eliminating the need for bulky and expensive external metallic shielding structures. Since
the bandwidth of single mode fiber is nearly unlimited, a single fiber optic interface can consume a small
percentage of space required by multiple conventional connectors. Panel density has become a key
demand as manufacturers of 1RU servers are seeking ways to move terabits of data from these tiny
front panels. Copper connectors of all types will likely rule the world of electronic products for many
2 -2
years into the future, but the handwriting is on the wall.
Connector Manufacturer Issues

Connector manufacturers are dealing with a number of issues that will likely influence their long-term
growth curve. Some have always been part of the interconnect industry business model, while others
have begun growing in their impact. They include:
1. Connectors are fabricated from metal and plastic and are subject to material market swings in
terms of availability and cost. Gold is currently priced at $1,342.00 per ounce and is a
particularly volatile component of many high reliability connectors. Years ago when gold
reached record levels, connector companies instituted gold adders that compensated for the
rapidly fluctuating price of gold. Swings in the price of oil which has recently been on the rise
can influence the price of many plastics. Advances in the use of selective plating technology as
well as hedging the market have reduced the influence of material costs but still remain
significant variables that impact profitability.
2. There has been a wholesale transfer of connector manufacturing to offshore locations,

particularly in Asia. This transition has occurred not only to take advantage of low cost labor,
but also to provide local sourcing to the most rapidly growing markets for electronic products.
More recently we have seen connector design and marketing functions also migrating to Asia.
Along with the products, the advanced technology of design and manufacturing has been
transferred to this region enabling foreign-based suppliers both large and small to offer
technically competitive connectors.
3. Defacto and formally standardized connectors have become commodity products which offer
reduced profit margin while minimizing the ability to design unique features that can
differentiate a connector from competitors. The rise of system architectures defined by open
standards can concentrate volume on selected interfaces. The winning connector design must
be available for licensing to a host of global competitors, effectively driving prices and margin
down.
4. The race to manufacture connectors at the lowest possible cost is now leading the industry to
consider the use of robotic assembly. The latest class of robots is smaller, less expensive and is
designed to work along-side humans. Using machine learning, they are able to quickly and
easily learn new assembly tasks making them ideal for custom, low-volume assemblies. Once
adapted, the repeatability of robotic assembly results in exceptionally high reliability of the
finished assembly. The industry is nearing the point where automation of connector design
together with advances in 3D printing may completely alter the traditional time consuming and
costly process of soft-tooling, verification, and hard-tooling of new connectors. Foxconn
Interconnect Technology (FIT), a global manufacturer of connectors based in Taiwan, currently
employs over one million workers while making major commitments to increase their connector
assembly using robots, putting more price pressure on competitors.
5. Over the years connector manufacturers have tooled many thousands of connector types each
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of which may include a host of variations in pin count, plating and configuration. All these
variations required a unique part number. Years ago, connector manufacturers were able to
charge up-front tooling costs with their customers, but competitive pressures have largely
eliminated that practice. Some of these parts have become high-volume components, while
others simply fill out the product line. Maintaining all these part numbers for availability on a
global basis is a major documentation, logistic, and cost challenge. In some cases a variation
may not be tooled until a minimum size order is received. The use of laminated or modular
tooling that allows relatively simple adjustment of molds can produce a custom variation. The
problem remains particularly for military and industrial applications where legacy products may
have a 20+ year expected life. Maintaining low volume and end-of-life products necessary for
repair of this equipment is expensive.
6. The manufacturer of electronic connectors has been subject to a series of global environmental
protection mandates that have resulted in costly material and assembly adaptations. Starting in
2006 the European Commission required the elimination of several “hazardous” materials
commonly used in the manufacture and application of connectors including lead, a key
ingredient in traditional solder. Connectors containing these materials could not be sold in
European Union countries. The result was a scramble to find acceptable lead substitutes. To a
large degree the connector industry settled on pure tin, which required soldering processes to
raise reflow temperatures. Those higher process temperatures required further material and
component changes to avoid damage from the increased heat exposure. Still unresolved are
lingering questions about circuit failures due to tin whiskering. Efforts to increase recycleability
of electronic devices may result in additional changes to traditional materials used in
connectors. Exposure to new environmental mandates leaves connector manufacturers
vulnerable to increased material and documentation expenses with little ability to control.
7. Counterfeit electronic components have been an ongoing problem for the electronics industry.
Primarily focused on high-value components such as integrated circuits, counterfeit connectors
have been sold to OEMs for years, and detected only when they fail due to poor plating or
dimensional issues. Connector manufacturing resources that have migrated from the United
States to Asia could result in sufficient expertise to locally produce leading edge counterfeit
connectors that carry higher margins.
8. Wireless interconnects have been chipping away at traditional cable assemblies as consumer
demand for mobile products increases. Many commodity interfaces including RS232, DIN and
USB have been replaced with a variety of wireless protocols that range from Bluetooth to Wi-Fi.
As electronic devices continue to shrink in size, designers find it harder to make space for an I/O
or power connector. Apple Computer has been leading the way by designing ever-smaller
connectors and in some cases eliminating them entirely. It appears the industry has begun
settling on a specification for wireless charging, eliminating the need for another separable
power connector. The trend toward wireless mobility will likely continue and be served by ever
faster protocols including 5G. There is little doubt that expansion of wireless technologies will
result in higher connector usage in associated equipment, but traditional I/O and power
connectors and cable assemblies will be impacted.
2 -4
9. The cost of designing reliable high-speed channels that include premium PCB materials,
advanced signal conditioning features, precision layout of PCB traces and layers, and extra
shielding may be reaching practical limits making fiber optic alternatives more attractive.
Although the manufacture of fiber optic connectors requires extreme mechanical precision, they
are much smaller, use less material, and often are designed to terminate many fibers
simultaneously. A number of global optical connector manufactures have focused their product
mix specifically on optical interconnects and have developed deep expertise in the design and
manufacture of these connectors. While several large copper connector suppliers also offer
multiple lines of optic interconnects, they may not include the most advanced high-density optic
connectors, putting them at a disadvantage in the marketplace. Current interest in taking high-
speed signals out of the PCB and “flying” them over the board via twinaxial or fiber optic links is
growing and may become more common. This could result in a limit on sales growth as more
interconnects transition to optic alternatives.
It is difficult to determine which, if any of these issues are significantly influencing management of these
connector manufacturers to pursue entirely new avenues of growth. The fact that multiple connector
manufacturers are actively acquiring independent sensor suppliers indicates that they see sensors as a
valuable addition to their value added resources.
Rapid change in the electronic industry and recognition that failure to adapt to changing technology can
be deadly may be driving a select set of connector manufacturers to consider expanding into new
product segments that offer greater long-term growth potential. Device categories that offer synergy
with existing connector manufacturing, marketing and distribution are particularly attractive. Electronic
sensors may fit that description exceptionally well. Sensors have become a key element in the drive
toward establishing a seamless interface between humans and technology. Major connector
manufacturers including Amphenol, Molex, and TE Connectivity have offered several lines of sensors for
years. More recently we have seen much greater emphasis on this segment of their product line as they
increase their range of product offerings acquired through purchase of and investment in select
independent sensor manufacturers.
To a degree, these suppliers are using their long-established reputations for quality along with long-term
engineering and purchasing relationships with large original equipment manufacturers (OEMs) to
expand their product offerings and open up new avenues of sales growth. They see a path to increasing
their added value content by offering connectors, cable assemblies and sensors as a total connectivity
solution, benefiting both their customer as well as their bottom line. Rather than compete directly
against established major sensor manufacturers that offer a broad array of product, connector
manufacturers are selectively entering markets where they can offer specific technical experience or
marketing advantages. TE Connectivity in particular has clearly stated their focus on ruggedized
interfaces including sensors, while Amphenol has traditionally featured industrial grade interfaces.
Molex has developed extensive expertise in automotive connectors, an extremely harsh environment
for electronic devices of all kinds. Samtec participates in the sensor market by leveraging its electronic
packaging expertise.
This market research report explores the technology, products, and range of emerging applications for
electronic sensors, as well as the synergy between the sensor and connector industries. Chapters are
2 -5
devoted to reviewing the many types of sensors and the technologies they utilize as well as the many
applications that utilize sensors. The emerging role that sensors play in four specific large market
applications including automotive, Internet of Things (IoT), medical, and industrial control are discussed
in depth. Additional chapters are devoted to exploring emerging trends and applications that will be
impacting the market for electronic sensors as well as a chapter that defines market values of electronic
sensors by market sector and region of the world along with five-year compound average growth rate
projections.
2 -6
Chapter 3
Chapter 3 Introduction
The human body is a remarkable machine. In addition to all of
the bodily functions that occur autonomously, survival in our
challenging environment requires interaction with the physical
world. This is accomplished through a series of unique sensors
that provide the conduit of information essential for survival.
Our eyes are able to convert a narrow band of electro-magnetic

radiation into electrical signals that our brain uses to visualize
our colorful world. They also provide information that is used to
enable depth perception. Our ears detect vibrations with
frequencies from 20 to 20,000 hertz that give us the sensation of
sound as well as the direction of the source. Highly sensitive
structures in our ears also provide spatial position and balance data essential for upright mobility.
Although not near as sensitive as many animals, our sense of smell is measured as a percent of one part
per million depending on the specific odor. Closely associated to smell is our sense of taste that falls
into five basic categories of sweet, sour, bitter, salty and umami. Considered our largest organ, the
human skin contains a huge network of sensors with the ability to sense temperature and pressure
(touch). Each of these sensors converts external stimuli to electrical signals that are transmitted to the
brain for recognition and analysis required to formulate appropriate action. This collection of sensors
has served the human race well for many thousands of years providing input essential for survival in a
hostile world.
As our world became more advanced, complex

and automated, humans developed mechanisms
to extend and enhance our basic senses. First the
telegraph, and later the development of radio and
telephone extended our ability to hear people
from long distances. The Japanese military used
immense horns in the 1920’s to 1930’s to amplify
and detect the sound of incoming aircraft.
Television and now the Internet allow us to see
and hear people and places anywhere in the
world.
Much like these devices, electronic sensors are the

eyes and ears of electronic equipment. They are the bridge between conditions in the physical world
and electronic systems that can use this input to analyze and make desired changes. Electronic sensors
are able to detect and measure phenomena well beyond that of human sense organs. Sensors can “see”
well beyond the narrow red, green, and blue spectrum available to us. Radar detects and tracks objects
many miles away. Sensitive microphones are capable of detecting and measuring ultrasonic sounds.
Electronic sensors are capable of measuring and quantifying properties such as nuclear radiation,
magnetic and electric fields which are entirely beyond our human senses.
3 -1
Equipment that incorporates sensors may consist of one or more sensors that are connected to an
actuator that physically adjusts or makes changes to a system. A home thermostat uses a bimetallic
strip that senses local temperature. As the strip expands and contracts it actuates a switch that turns a
furnace or air conditioner on and off. More sophisticated systems include a degree of integrated
intelligence that utilizes input from one or more sensors to make programmed decisions for action.
There are literally dozens of sensor types that are designed to detect or measure everything from
temperature to geographic location. They serve critical roles that range from residential smoke alarms
to identification of incoming ballistic missiles.
General Sensor Types and Technologies

The universe of electronic sensors can be categorized into a series of general types:
1. Binary sensors that detect a specific condition such as fire or water.

2. Quantitative measurement such as liquid levels and biomedical conditions.
3. Thermal sensors
4. Optical sensors
5. Electric field sensors
6. Magnetic sensors
7. Position sensors
8. Data-reading sensors such as RFID
9. Meter-reading sensors
10. Material composition sensors
11. Weather sensors
12. Specific chemical or gas sensors
Sensors utilize a variety of technologies including infrared, magnetic, radiation gravity detection as well
as piezoelectrics, acoustics, and ultrasonics. They are fabricated using materials as simple as bi-metallic
strips to an entire class of sensors that utilize advanced microelectromechanical manufacturing systems
(MEMS) technologies.
The Internet of Things will depend on a host of standard and

advanced sensors of all types and represents a huge current
and expanding market for sensors. Video cameras now
installed on most urban street intersections as well as the
Internet linked sensors that detect occupants and control room
temperature are only the first wave of sensors that will
become even more pervasive in the next few years.
Typical cars today contains dozens of sensors that will grow in

number to enable the next generation of driver assist
functions. Embedded sensors automatically adjust air and fuel
to optimize each cycle of the combustion process while others
warn of low tire pressure. Future autonomous vehicles will be studded with internal and external
3 -2
sensors that will detect and enable communication with traffic control devices as well as other cars.
Sensors can also be a source of frustration as that pesky “check engine” light is often the result of a mal-
functioning sensor. One forecast puts automotive sensor usage at 10 billion devices per year by 2020.
Low-cost sensors are typically used in a variety of consumer applications while other more sophisticated
sensors have been adapted to the specific requirements of individual industries including medical,
industrial control, transportation, military, avionic as well as oil and gas exploration. Sensors used in
medical equipment for instance must be accurate and withstand multiple sterilizations, while those in
military must be rugged and reliable in harsh environments.
Similar to the electronic connector industry, the universe of sensor manufactures consists of a relatively
few large suppliers, a larger field of mid-sized manufactures and literally thousands of very small
manufacturers. Identifying the largest sensor manufacture is depending on the types of sensors
manufactured, region of the world or markets served.
Current overall industry leaders include Bosch Sensortec,
Texas Instruments, and STMicroelectronics, Siemons and
Honeywell as well as a host of smaller manufacturers that
supply sensors for specific markets or applications. The
incredible sales potential of sensors has attracted the
attention of several major connector manufacturers that are
looking for new avenues for growth. The result has been a
flurry of acquisitions that has enabled leading connector
manufacturers such as Amphenol, Molex and TE Connectivity
to increase their presence in this market. The objective is to
exploit the synergy between connectors and sensors by
expanding their portfolio of sensing devices and related cable
assemblies. Several of these suppliers have already
established extensive lines of sensors designed for
automotive applications. Rather than try to compete in the
low cost generic sensor market, these suppliers are focusing more on higher performance/ higher
margin sensors used in more specialized applications such as transportation, medical, industrial,
military, and aerospace.
Flow rate, temperature, position, and pressure

sensors that are used in industrial automation for
instance fit this market niche nicely. The ability to
utilize real time data from a network of sensors can
enable the management of a process with precision
as well as identify areas for improvement. Industrial
control equipment designed to support Industry 4.0
will rely heavily on a network of sensors that will
generate the data to be exchanged within the “smart
factory.”
3 -3
Sensor fusion refers to systems that utilize multiple sensor inputs in a network to achieve a result.
Working with multiple inputs, systems have begun using artificial intelligence to tightly control a process
to a degree not possible in the past. A developing problem can be detected and corrected long before
actual failure causes a disruption in production. Robots using artificial intelligence can utilize input from
an array of sensors to quickly learn new tasks while safely working alongside humans.
Many consumer product related sensors are soldered directly to a PCB, while others, particularly those
in medical, industrial control, and mil/aero applications where long-term reliability is a requirement may
incorporate a separable interface. Applications in these commercial and military markets where high
reliability in challenging environments is essential create a sweet spot for connector manufacturers. The
ability to offer both the sensor and interconnect can allow access to an OEM design team early in the
new product development cycle. Access at that point can potentially open the door to proposing the
full range of connectors and cable assemblies required throughout the system, a classic value-added
situation.
Military demands for unique sensors in such diverse applications as chemical / biological agent
detection, night vision, and laser weaponry are driving advances in sensor technology. The ability to
make sense of multiple streams of high-speed sensor input now exceeds our ability to sort out
actionable data. The result has been the creation of the Mathematics of Sensing Exploitation and
Execution project which is focused on developing autonomous systems capable of analyzing images and
actions in real time.
The growth of electronic warfare will be another aspect of continuing sensor research. Space-based
sensor systems will be required to provide the degree of surveillance necessary to support future
security operations. Demand for exceptionally high quality images will continue to spur development of
low light / high resolution sensors.
Concerns about “Big Brother” watching over us and the loss of privacy have sparked a lively debate
about the rise of ubiquitous sensors, but the popularity of consumer devices that are constantly
monitoring us, and video surveillance of nearly every city street corner is making the debate moot.
Growing concern about local as well as national security as well as anticipation of the advantages of
autonomous transportation and consumer convenience will likely result in greater acceptance of these
intrusions. We will continue to co-exist with a rising tide of sensors that will provide both advantages as
well as challenges. Synergy between advanced sensors as well as related connectors and cable
assemblies is opening new avenues of growth and profit for those in the interconnect industry that are
capable of investing in this market.
3 -4
Chapter 4
Chapter 4 Sensor Types and Technologies

Introduction
Electronic sensors or transducers are broadly defined as
devices that convert energy from one form to another.
Sensing devices in use today typically convert a measured
mechanical, environmental, optical, audio, electrical, or
chemical input into a representative electrical signal that can
be used to quantify a specific property. The transduction of
a condition into useful electrical signals requires that sensors
use a variety of technologies that exhibit change over a
range of measured values. They may include temperature to
change of resistance, photons to current, thermal radiation
to voltage, humidity to capacitance, and position to
inductance. Pacific Northwest National Laboratory
A typical application that uses sensors consists of one or more sensing devices that detect specific
properties in the environment and send analog or digital information directly to an actuator or
translator device. In applications where a degree of intelligence is required, the data is delivered to a
microcontroller or embedded processor for analysis, and necessary calculations to determine if changes
are required. An associated program will compare reported conditions and initiate adjustments via
signaling to an appropriate actuator which makes necessary adjustments or displays the results.
Sensors may be located in a remote location and utilize a wired or wireless RF link for connectivity. The
ability to simultaneously measure conditions in multiple locations is an absolute requirement in many
production control systems making sensors connected to a network a key requirement. Sensors can be
located in places dangerous or impossible for humans to work.
A classic example of a closed-loop system uses a sensor-generated feedback loop to adjust a process for
variable conditions and ensure consistent output. A common clothes dryer is an example of a simple
sensor managed heat control system.
4 -1
The electrical connections between each of these system elements have traditionally used copper
conductors in shielded or unshielded cable assemblies. More recently we are seeing RF links to a local
network or the cloud becoming more common, especially in industrial control networks where many
sensors located throughout a manufacturing process must communicate in a noisy EMI environment.
Higher levels of chip integration that combines multiple sensors and processors as well as wireless
communication chips in one package are also on the rise.
Sensors fit into two broad categories

of passive and active types. Passive
sensors derive their input directly
from their immediate environment.
A CMOS imaging sensor and a
microphone are considered passive
sensors. Active sensors emit some
form of energy and measure the
reflection. A Lidar ranging sensor
and an ultrasonic motion detector
are examples of active sensors.
Active sensors require an external
energy source in order to operate,
while passive sensors require no power.
Sensor Types
The universe of electronic sensor types continues to grow as our world becomes increasingly dependent
on automation. They now include:
• Temperature
• Humidity
• Fluid levels
• Gas pressure, absolute and differential
• Weight
• Stress
• Force
• Proximity
• Dust
• Imaging, both visible spectrum, ultrasound and thermal
• Location
• Direction
• Magnetic fields
• RF energy field strength
• Motion
• Material quality (liquids and solids)
4 -2
• Level
• Wind speed/ direction
• Electric current and voltage
• Compression / tension
• Turbidity
• Shock
• Vibration
• Acceleration /Speed
• Pitch, Roll, Yew
• Flow rate
• Audible and ultrasonic sound
• Gesture / facial recognition
• Heart rate
• Sound
• Smoke
• Electrical conductivity
• Pulse Oximetry
• Touch
• Displacement
• Noxious gas
• Base/acidity
• Nuclear radiation
• Geomagnetics
• Speed
• Visible / ultraviolet/ infrared light including color
• X-Rays
• Chemical composition
• Thickness
• Distance
• Torque
• Rotary angle
• Biometric functions
Sensors may differ in terms of accuracy, physical size / form factor, stability over temperature variations,
reliability, analog/ digital output, environmental resistance, type of connection as well as cost. Some
types of sensors are directly exposed to the measured property while others feature non-contact
measurement.
4 -3
Sensor Technologies
The basic principles that enable sensors to generate measurable electrical output vary widely.
One of the simplest forms of sensing device

uses the principal of differential expansion of
metals. Two different metals bonded together
will bend as the ambient temperature changes.
At a fixed or adjustable temperature point the
contacts will close to actuate a circuit. Many
home thermostats work on this principal.
A Hall Effect sensor generates an output voltage in

response to its exposure to a magnetic field and is
often used to detect proximity, positioning, electrical
current sensing, and rotational speed.
Photocells convert incoming photons to a

voltage output while photo-resistors change
resistance according to the intensity of light
they are exposed to.
Portable heat sensors measure

temperature of surfaces without direct
contact.
4 -4
Air or gas pressure sensors can

measure absolute or differential
pressure.
Pressure can be measured using

several different technologies
depending on the accuracy and
durability required by the application.
The proximity, direction, and speed of moving objects can be

determined by measuring the time-of-flight of an optical,
sonic or RF signal reflected from a stationary or moving
target.
4 -5
Location and direction sensors may use

radio transmission from a network of
GPS satellites to also measure speed.
Biometric sensors used in fingerprint

identification systems detect tiny variations in
skin ridges and valleys.
Touch sensors use changes in capacitance as well

as interruption of a grid of infrared beams.
Motion sensors detect variations in sonic

or optical reflections to detect movement
in a defined field. These reflections can
also be used for navigation and ranging
using the Doppler Effect.
Infrared detectors sense changes in heat

radiating from people and animals.
4 -6
Pressure, strain, twist, force and vibration can be measured by the charge generated by piezoelectric
materials which generate a voltage when pressure is applied.
Unique properties of a specific material can

be used to provide accurate temperature
measurements. A thermally sensitive resistor
also known as a resistance temperature
detector (RTD), such as a thermistor changes
resistance proportional to the exposed
temperature.
A thermocouple uses the thermoelectric effect

of joining two dissimilar metals to generate a
temperature- related voltage.
4 -7
Solid state CCD and CMOS based

image sensors are able capture
high resolution color images.
Touch, proximity, liquid level and material thickness sensors use a variety of technologies depending on
the specific requirements of the application.
Non-contact capacitive sensors utilize a

change in electric field caused by the
introduction of a non-magnetic material. The
capacitance of a circuit can also be altered by
applying direct pressure to a capacitive plate.
Non-contact inductive sensors detect changes in an oscillating magnetic field generated by the sensor.
When a metallic object enters the field, eddy currents change the reluctance of the magnetic circuit
triggering a switch.
4 -8
Water quality or turbidity can be

measured using either transmitted or
scattered light beams.
New Zinc sulfide nanoparaticle based chips identify and

measure concentration of various gasses.
The list of senor types and the technologies they use continues to grow.
4 -9
Micro-Electromechanical-Systems Sensors
A rapidly growing segment of the sensor market
includes devices that are fabricated using
microelectromechanical systems (MEMS)
technology. MEMS technology defines devices
that are manufactured using microfabrication
processes to produce exceptionally small
mechanical and electronic structures. MEMS
devices can range in size from a few millimeters
down to less than one micron. A unique
characteristic of MEMS devices is the ability to
produce moving elements on such a small scale.
Using fabrication processes similar to that used to manufacture semiconductors including deposition,
lithography and etching, large wafers of MEMS devices can be created with incredible complexity and
low cost. MEMS technology has enabled the mass production of chip level devices such as large arrays
of micro mirrors, each of which can be programmed to be moved independently. Digital light processing
chips featuring several hundred thousand microscopic mirrors from Texas Instruments enabled DLP
large screen digital projection displays.
Light detection and ranging (LIDAR) systems, an integral part of the evolving autonomous transportation
revolution, utilize MEMS sensors that offer accuracy and durability while consuming minimal space.
4 -10
MEMS sensors and actuators are one aspect of the overall solution facing system designers who are
demanding increased product performance in miniaturized packages. MEMS devices are a key
technology in the ongoing trend to system miniaturization. The fact that MEMS devices typically
consume less power than conventional devices, addresses another critical design requirement,
especially in mobile or remotely installed equipment.
The ability to integrate multiple MEMS sensors, ASICs, microprocessors, and wireless communication
chips on a single substrate has accelerated the movement toward “smart” sensing devices that are able
to process input from multiple sensors and transmit a higher level of useful information.
Advanced system on module sensors has made the packaging of sensors a critical aspect in the design of
next generation sensors.
MEMS based sensors including accelerometers, gyroscopes, compasses, high-resolution cameras,

microphones, and inertial modules have been a key in enabling the host of advanced functions of smart
phones.
4 -11
Recent advances in MEMS technology has allowed engineers to build devices that integrate precision
channels, valves and reaction chambers that can be
used to produce complete “lab on a chip” devices.
These miniature factories can be integrated into
portable equipment that can quickly analyze fluids
and gasses in medical and pollution monitoring
applications.
Research continues with the objective of developing

microfluidic analyzers that can continuously monitor
a variety of blood constituents as well as pathogens.
Low cost microfludic sensors could provide early

detection of cancer cells, especially in regions of the
world that have limited medical facilities.
4 -12
Sensor Packaging
Sensors are available in a wide variety of form factors
depending on their intended application.
Board mounted devices can be attached using fully

automated assembly equipment to minimize
component as well as PCB assembly cost.
They can be supplied in industry standard package profiles to

facilitate automated assembly.
Sensors manufactured using MEMS technologies are the solution in space-sensitive

applications such as mobile devices.
PCB mounted MEMS sensors include variations that are mounted in hermetically
sealed cans or shielded from electromagnetic interference.
Sensors such as ambient air pressure or humidity must be

packaged to allow access directly to the sensing element. Open
cavity molded or metal covers are typical.
In some cases, the form factor is dictated by the function of the device such as a
time-of-flight distance sensor that integrates a laser emitter and receiver as well
as a microcontroller.
4 -13
MEMS devices can be packaged to include multiple sensing

elements to provide a complete solution. Pitch, roll and yaw can
be measured using several technologies including a three-axis
accelerometer as will as a gyroscope and magnetometer. All of
these functions can be built into a single MEMS sensor.
Implantable “neural dust” sensors can track, record and

transmit data related to medical conditions.
Chips intended for injection must be fabricated from

materials that are compatible with living tissue
4 -14
Sensor Interconnect
The vast majority of sensors used in high volume / cost sensitive consumer and some commercial
applications are soldered directly to a PCB.
Sensors maybe connected with discrete wire or cable

assembly, especially when the associated electronics
are located remote from the sensor.
Bendix manufactures a brake-wear

sensor/cable assembly that is built to
withstand the harsh automotive environment.
Termination to flexible film is a common option, especially for

image sensors or where the sensor may experience movement
or vibration.
Flexible film with multiple components can also be

folded to fit into small enclosures.
4 -15
A separable connector may be integrated into the sensor

package where replacement or potential for change of location is
important.
Sensors designed for applications in industrial control, military

and aerospace applications are typically packaged for durability
and reliability in harsh environments. Pluggable interconnects
may feature rugged
military, or
environmentally sealed
connectors
Connector types vary and may include standard M12 sealed

industrial connectors.
Sensor modules that

incorporate a microcontroller
and wireless transmitter
simplify the process of
deploying an array of remote
sensors.
4 -16
Sensors can also be integrated into an application specific

housing. Molex manufactures an automotive crash
detection module that includes a separable electrical
connector in a molded assembly.
Sensors designed for aerospace applications are typically

integrated into robust metal enclosures.
Sensor assemblies may be designed in very specific and

sometimes standardized configurations with tightly defined
dimensions as well as pluggable electrical interface.
Medical sensors must not only be rugged enough to survive regular

cleaning and long service life, but also must be ergonomically correct
and aesthetically attractive.
4 -17
Sensor Fusion
Similar to humans, advanced electronic systems often require more than a single input. An individual
sensor can only report on one condition providing only a narrow perspective that may not be true due
to sensor limitations. Failure of a single sensor blinds the system. Combining the output from multiple
sensors provides a much more accurate picture of the environment. An array of sensors can deliver
measurements of different parameters, positions, and times to increase confidence in the results. Input
from two similar sensors can be compared to increase accuracy as well as provide a degree of fault
tolerance. Two low-cost sensors may be a better solution than relying on a single higher reliability
sensor. Sensor fusion is the process that enables the electronic systems to expand their view of the
world from simple sensing to true perception.
Combining two or more sensors into a single device has become the preferred packaging solution in
support of a host of new applications.
Data from each sensor can be

fused and intelligently allocated
to an application -specific
processor to produce a more
definitive interpretation of the
environment. This data stream
becomes the input for algorithms
driven computation that
completes analysis of the data
and produces a final output.
Applications for instance that

require stereoscopic vision,
requires the combination of two-
dimensional data from two
separate cameras.
A relatively simple example of sensor fusion is an automated medical device that measures
cardiovascular fitness. This is accomplished by assessing the time it takes for skin tone to return to
normal color following a controlled compression.
4 -18
The skin is compressed as the air bladder is

inflated. The photodiode and optical
sensor measure the time it takes for the
color of the skin to return to normal while
the thermistor tracks skin temperature.
More complex systems may require multiple sensor inputs in order to fully quantify the environment.
The smart phone contains many sensors which are enabling designers to create new innovative
applications that range from diagnosing medical conditions to situational awareness.
The much-anticipated fully autonomous car is an example of an application that will require the flawless
fusion of high-speed data from dozens of sensing devices that must be constantly analyzed in real-time
in order to safely navigate a vehicle. Data on the ambient conditions sensed will become one of many
factors that include input from area vehicles and traffic control systems. Decisions made by complex
programs and algorithms will make choices based on how a vehicle will act in emergency situations; a
daunting task that will likely take years to sort out.
The internet of things (IoT) and Industrial IoT (IIoT) are expected to generate literally billions of
connected devices, many of which will features capabilities that require the simultaneous fusion of data
from multiple sensors.
4 -19
Chapter 5
Chapter 5 Sensor Applications

Introduction
Sensors have become essential components that enable the myriad of electronic devices we utilize
every day. Basic sensors using simple bi-metallic springs have controlled the temperature in our homes
for years, while new highly engineered sensors in a host of medical applications save lives.
That basic wall thermostat is being replaced with a new breed of environmental controller that
maintains precise room temperatures, remembers individual preferences and detects their presence
while being adjustable via a cellphone app.
Today, sensors play essential roles in the function of millions of

devices, that fall into the general categories of consumer,
commercial, IoT, medical, industrial, automotive, communications,
and military/avionic. Each of these categories may include dozens of
sub-categories making clear delineation between application
segments less than clear. For purposes of this report we have
assigned representative applications under eight general categories
which may in fact logically fall into multiple categories. For
example, wearable sensors can track fitness, monitor serious
medical conditions as well as detect hazardous ambient conditions
encountered in industrial and aerospace applications.
The following pages illustrate the diversity of applications where electronic sensors play a critical role in
each of eight industry segments.
5 -1
Consumer Electronics
Sensors designed for use in consumer products must provide a combination of acceptable performance
with minimal size and price. Expected reliability of these devices can range from a few years to the life
of one set of batteries. Since consumer products often represent huge production volumes,
components must be compatible with fully automated assembly equipment and be globally available.
Sensors designed for Smart Home

applications such as fire, smoke, security,
water and temperature have been on a slow
but continuous growth curve for years. Some
of these sensors are wired directly to a device
while others connect wirelessly and can
operate for years powered only by a coin cell
battery. Recent advances of new device
platforms such as the Amazon Echo and
Google Home are stimulating progress in
product compatibility and ease of user
installation, boosting Smart Home adoption.
Individual LED light bulbs that sense room occupation are now available at reasonable cost. Devices
now on the market detect open door status and impending failure of mechanical systems by measuring
vibration and heat. Embedded sensors make centralized management of HVAC, security, power
consumption and appliance operation possible. Homes in the future are expected to be festooned with
an array of sensors that will enable personalized “thermal clouds” that will increase comfort while
reducing energy consumption.
Wearable electronics is one of the product

categories that bridge between multiple application
segments. The Apple Watch and FitBit are prime
examples of consumer wearables that have been
retail successes while Google Glass went back to
the lab for redefinition. Wearable devices that
monitor athletic performance are on the rise and
incorporate sensors that provide movement
recognition on the wrist, in shoes and clothing.
The simple pedometer that counts steps is now

evolving into watches that provide orientation and
personal navigation using GPS and gyroscopic sensors. These smart devices analyze recorded data to
make personalized recommendations for improved workout efficiency and effectiveness.
5 -2
Wearable products are evolving into at least eight general application categories.
1. Medical: Vital signs monitoring,

therapeutic devices.
2. Security: Automated personal
identification for home, office, automobile
access.
3. Wellness: Track stress, weight, obesity /
diet management.
4. Fitness: Performance, virtual coaching,
goal management.
5. Lifestyle Computing: Gaming, time
management, data access.
6. Communications: Voice, text, social media.
7. Glamour: Integrated lights, changing
patterns, emotion tracking/display.
8. Entertainment: Access to music, radio, streaming media.
Wearable consumer sensors are being designed into clothing that ranges from hats that monitor and
generate heat to shoes that that can measure impact. Smart fitness performance clothing utilizes
imbedded electromyographc sensors that measure the degree of electrical activity generated by
working muscles. Muscle activity, heart rate, and respiration data is transmitted to a smartphone for
analysis in real time via Bluetooth.
Wearable electronics that include sensors are

being developed for applications where an
individual is exposed to hazardous
environments. Firefighters for example, could
benefit from continuous biometric monitoring of
their physiological state, and receive a warning
when limits are exceeded. Integrated sensors
collect and transmit data that monitors such
parameters as body temperature, respiration
rate, heart rate, electrocardiogram as well as air
quality. An algorithm would process the data and
send an alert if these criterion are determined to
be at a dangerous level, either singularly or in
combination.
5 -3
Next generation wearables now in

development will feature sensors integrated
directly into the fabric, making smart
garments indistinguishable from conventional
clothing.
Emerging technologies enable the ability to print

conductive circuits directly on stretchable fabrics,
opening entirely new applications for sensors as well
as a new class of interconnects.
Smart textiles will benefit both the user and retailer. L.L.
Bean, famous for rugged outdoor clothing will be integrating
sensors into their jackets and boots to gain insight on how
their products are being used in real world environments.
The Loomia Electronic fabric includes a layer of flexible
circuitry and connects to a small device that uses near field
communications to download recorded data. L.L. Bean plans
to use the data to identify product performance as well as
new product opportunities.
ShockBox concussion management sensors are designed to be

mounted in sports helmets to identify potential concussion in
real time. Head impact triggers the wireless transmission of
data to the ShockBox app which calculates the magnitude and
direction of a hit as well as its correlation to brain injury.
Coaches and physicians on the sidelines can monitor the
degree of impact on each player and bench a player to
prevent further damage resulting from a concussion.
Optimized sensors are available for hockey, football, winter
sports, lacrosse, equestrian, and BMX riders.
5 -4
Consumer electronic products such as video gaming consoles, notebooks and cameras rely on a variety
of sensors that range from gyroscopes and proximity sensors to image and location sensors embedded
on digital cameras.
Gesture recognition and interpretation

technology uses a variety of sensors that can
translate hand motion into input for gaming
devices today, and is being considered for
future use in smart phones and vehicles.
They also may have far reaching applications
in medical and industrial environments
where non-contact, language agnostic
communication with a device is required.
Applications in the food processing and
presentation industry where handling can
result in contamination are also likely
candidates for gesture control.
5 -5
Internet of Things (IOT)

Defined as a network of connected devices
among people, processes, information and
things, the Internet of Things is currently in an
early stage of implementation. With forecasts of
up to 50 billion connections by 2020, IoT is
expected to create entirely new products and
services unimagined today.
Since the term “Internet of Things” was first

coined in 1999, the scope of this technology has
been expanded to include nearly every device we
utilize today, both electrical and mechanical. The
Internet of Everything (IoE) is even more
inclusive and is expected to be pervasive in every
aspect of our life.
Industry executives see this revolution as the rise of intelligent systems that exhibit four key
characteristics:
1. Connected to share information, communicate with other IoT devices and the cloud.
2. Secure to protect the integrity of data.
3. Managed to allow remote monitoring, repair, and updating.
4. Intelligent, capable of adjusting to change, new input, and adaptation.
Recent major breaches of security at Equifax and Facebook demonstrate that much more attention must
be applied to security if the IoT is to achieve its full potential.
Using multiple embedded sensors and processing power, emerging IoT devices gain capabilities and
value with the ability to learn tasks and preferences to predict the future based on past experience, and
act within a defined range of choices.
A fully deployed IoT will combine the resources of Big Data, the cloud and enhanced wired and wireless
communication channels to deliver predictive intelligence in real time. Large networks of connected
sensors will gather information that can be used to optimize everything from the temperature of your
home to balancing the energy load on our national power grid. Embedded sensors will enable smart
monitoring with instantaneous response to emergencies and the ability to track personal preferences
and buying patterns leading to highly targeted marketing of products and services.
Many initial applications of IoT have centered on consumer applications. The objective is to make
everyday consumer devices smart, trackable, and connected to increase performance and function
while minimizing human intervention. The IoT is becoming the mechanism that links applications
related to home environmental management, security, communications, and entertainment. Sensors
embedded in almost every appliance will enable devices to talk directly with each other, analyze the
5 -6
results and present appropriate responses to consumers.
The smart home is becoming the early focal point of many IoT consumer devices in a market that has
languished for years as proprietary standards competed for dominance. New wireless IoT based devices
promise ease of installation and interoperability among multiple suppliers.
Smart home products already in the development pipeline will result in devices that will link the full
array of home safety, comfort, and convenience equipment including:
• Smoke, carbon monoxide, natural gas and water detection alarms.

• Remote heating, humidity, and air conditioning management.
• Home security locks, surveillance cameras, and intrusion alarms.
• Energy conservation management of appliances including the status of utilities.
• Lighting, including variable color and intensity as well as occupancy detection.
• Automated irrigation based on weather forecasts and local conditions.
• Infotainment, preferred music, video, news, and social media.
• Occupant emergency recognition and EMT response.
• Severe weather alerts.
• Automated home system maintenance alerts.
Security systems that monitor every aspect of the home are quickly evolving from hard wired systems
which are expensive to install and difficult to reconfigure, to wireless systems that automatically link a
network of sensors to a central hub.
Smart refrigerators on the market today feature

large touch screens and voice recognition. They
are able to track the contents and suggest
recipes for meals using available foods. Video
cameras generate images of the contents which
can be viewed on a smart phone.
The Amazon Echo and Google Home devices

have begun acting as a voice interactive hub for
an increasing array of smart home services.
The internet connected smart phone has emerged as the primary device by which to monitor and
interact with many of these IoT applications. Smart phones continue to evolve with an expanding array
of sizes and capabilities quickly obsoleting the latest iteration within six months. Users can scan bar
codes to determine the best retail price, deposit checks, view home security video while on vacation,
and pilot a drone with live video. The versatility of smart phones together with constantly increasing
5 -7
sensor and processing power, display quality, and cellular coverage enable them to adapt to new
unimagined applications, while voice and gesture recognition along with biometric verification make
interaction more user friendly.
The promise of huge retail sales has spawned a

wave of consumer related IoT devices.
The Mimo baby monitoring system tracks

breathing, body position, skin temp, activity
levels and wake/sleep in real-time. A low
power Bluetooth connection allows continuous
monitoring from a smart phone. Advanced
sensors located in a “turtle” are removable
from the Mimo kimono.
Personal digital assistants have been in the market for several

years. Siri, Alexa, and Google home are making rapid progress
in introducing new capabilities. By integrating location and
voice sensors, mapping software, GPS, smartphone apps, RFID
tags and wireless Bluetooth and Wi-Fi connectivity, new
devices can utilize accurate sensing technology to enable easy
tracking of everything from energy usage to doctor
appointments.
Emerging semi- and fully autonomous

vehicles are decked out with dozens of
sensors that manage almost all functions of
the car as well as share data on location,
speed as well as communicate with other
vehicles and automated traffic signals.
Sensors designed for applications in
automotive, trucking, heavy equipment,
agriculture, and rail transportation must be
highly accurate and reliable while
functioning in extremely hostile
environments.
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At the other end of the spectrum are somewhat less

mission critical products such as FitBark which uses
multiple sensors to monitor activity levels, quality of
sleep, distance traveled, calories burned and overall
health of your dog 24/7.
An extreme example of wearable electronics is a oral

retainer modified with an integrated sensor that
monitors the amount of salt intake and wirelessly
transmits data to a smartphone for recording and
display.
Scientists have even investigated a 2mm X 2mm

sensor that when attached directly to a tooth, the
type of foods consumed and their nutritional value
can be monitored.
There is little doubt that some of these IoT sensor applications boarder on the frivolous. Many of these
initial products will fail, but others that bring real convenience and value to the consumer will thrive.
Newer IoT products are demonstrating practical solutions that indicate that the Internet of Things may
be evolving to the Internet of Useful Things (IoUT).
At least initially, huge networks of connected sensors will result in billions of data streams which could
overwhelm the existing Internet infrastructure until smart analytics become capable of making sense of
such disparate information. The concept of edge or “fog” computing networks which places lower level
computing resources closer to the source of incoming data is one possible solution being considered.
Latency can be reduced for applications that require minimal computing power, while core processing
remains available for heavy duty applications.
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Formidable challenges in terms of security, bandwidth allocation, power conservation, development of

standardized protocols as well as ethical questions regarding the use of collected data must be
addressed.
The U.S. market value of just the consumer segment of IoT products and services is expected to reach $1
trillion by 2020 with billions of connected devices. Incredible growth is expected in each of the three
key consumer categories of health/fitness, home, and transportation. Industrial IoT adds many more
opportunities.
The Internet of Things is still in an early stage of implementation, but holds exciting promise for
changing so many aspects of our daily life. Although the Internet of Things tends to focus on connected
devices, in reality the IoT will be the delivery mechanism for a universe of services that will free humans
from routine tasks as well as provide entirely new capabilities. Sensors will play an essential role in the
realization of this technology.
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Industrial Automation, Process Control

We are in the process of moving into a world where industries are adopting automated technology that
promise to improve quality and increase production rates, while reducing cost. Manufacturing
processes have undergone a series of major advances that have been defined as;
Industry 1.0 Adoption of water and steam mechanical power as opposed to total manual labor.
Industry 2.0 Introduction of mass production; identical products using standardized parts assembled
in a production line.
Industry 3.0 Utilization of computerized electronic control systems to automate processes, insure
consistent quality, manage inventory and distribution.
We are now at the cusp of Industry

4.0 where a network of sensors,
distributed throughout the
production process is capable of
communicating to a production
management system as well as
among themselves. The resulting
“smart factory” is revolutionizing
how products are made.
The Industrial Internet of Things (IIoT) is a subset of the IoT and is a channel where sensors, computers,
networks and the cloud interact in real time to generate information that can improve manufacturing
processes. Machine-to-machine communication (M2M) is immediate, continuous, and provides the
input to systems that generate predictive analysis resulting in optimization of the entire process.
Industrial IoT control systems that utilize sensors differ from consumer IoT devices in several critical
ways.
1. IIoT devices are focused on generating actionable data that provides peer-to-peer management
with minimal human intervention.
2. Devices are manufactured to industrial strength standards for long-term reliability in electrically
noisy and physically challenging environments.
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3. They must be instantly adaptable to node failure and Internet interruption.
4. They should be compatible with legacy wired and wireless infrastructure and multiple industry
standard protocols.
5. They must incorporate hardened security measures.
With reliability and durability being absolute requirements, costs of all components that make up an
industrial IoT system are significantly higher than a consumer IoT device.
Sensors not only detect abnormal vibration and temperatures to initiate preventative maintenance, but
can manage the output of a manufacturing line to closely match market demand. Sensor nodes provide
links to the cloud where data is stored and shared. Closely managed manufacturing processes can send
immediate alerts to drifting acceptable quality parameters. Corrections can be automatically adjusted
or the line shut down to minimize the production of scrap.
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Industry 4.0 smart factories incorporate a wide range of capabilities that impact the bottom line.
The advent of “smart factories” enables much

improved manufacturing processes and is generating
demand for related sensors.
Electronic sensors designed for industrial applications differ from sensors destined for consumer
products in several significant ways including durability, accuracy, and reliability over long periods of
service life. The factory floor can be a nasty, hostile environment that can include strong caustic
materials, noxious gasses, high temperatures, shock, vibration, as well as moisture. Sensors must be
packaged to withstand this environment for many years. As a result industrial sensors are often
designed with stainless steel shells and may have wire leads for termination to a barrier block on a
controller.
Some industrial sensors feature an integrated standard connector interface such as M12 to insure a
reliable connection.
Industrial sensors such as this Turck angle sensor

feature ruggedized and waterproof housings that
can survive many years of exposure to harsh
environments.
Industrial robotic equipment offers a particularly rich

potential for high-reliability sensors. Robots require
extensive information about their environment in
order to function effectively. An array of sensors
provides a robot with data on its operation as well as
immediate environment.
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Today we are seeing all types of robotic devices that range from assembling vehicles to cleaning up
nuclear waste. Originally focused on heavy industrial and hazardous applications, robots that have the
ability to learn new jobs are now appearing in
warehouses and hospitals as well as the factory.
One of the most significant advances in robotics

has been in their ability to work collaboratively
with humans. In the past, industrial robots were
isolated from humans as their rapid movements,
strength and inability to recognize and avoid
people in the area, posed a serious safety threat.
Robotic work stations were gated or enclosed to
prevent contact.
Newer machines have been designed to directly

assist humans and can now be employed in
“cage free” areas. Robots use a combination of force limits, multi-axis force, and torque sensors as well
as sonar and vision systems to detect human presence. This new breed of collaborative machines is
being adopted by many smaller companies that can take advantage of the increased productivity that
robotics can offer.
Robotic devices have become much more user friendly. Programming a robot has evolved from the use
of arcane robotic programming language to an intuitive teaching style process, which makes the
redeployment of a robot to a new task much simpler and quicker. A robot capable of performing
multiple tasks is much easier to economically justify.
Small stationary robots are a growing market

segment. Introduction of relatively low cost,
table-top robotic arms are rapidly expanding
the range of applications that robots are
performing. These versatile machines are easy
to program for fast set-up, consume little
space and are ideal for light-weight repetitive
tasks.
Robotic hands have been refined to the point

that they can grasp fragile items without
damage. Covered with a soft skin-like rubber
embedded with pressure sensors, these hands
take on a remarkably human-like feel.
Robotic devices rely on an array of sensors that provide it a view of its environment as well as managing
its internal functions. Sensors commonly used in robotic equipment include, thermal, photocells,
infrared and ultrasonic transmitter and receivers to detect proximity and distance. Inertial, acceleration,
GPS and gyroscopic sensors report position. A compass and inclinometer assist with orientation. Force
5 -14
and pressure sensors prevent damage to products they are handling as well as people working around
them. Microphones and speakers allow voice interaction. More advanced robots incorporate vision
systems that can identify objects as well as individual people.
In addition to high levels of performance and reliability,

these sensors must consume as little space as possible in
these often cramped enclosures.
Advances in industrial robotics are beginning to spawn a new

category of robotic devices. Robotic assistants are starting to
appear in hospitals, offices and hotels where they perform
routine tasks such as delivery of medications, meals, and
laundry. Robots are now responding to calls for room service
items. These early devices are studded with sensors and
software that enable them to interact with the world around
them. Many newer robots are also beginning to incorporate a
form of machine learning capabilities using sensor input.
Consumer level robots have been relatively slow in gaining

entry to the market due to price but also suffer from the
difficulty associated in programming them. We are now
starting to see robotic companions designed with open-
sourced platforms that will enable developers and users to
simplify the process of making these robots perform useful
tasks right out of the box. The result will be greatly increased
volume potentials for electronic sensors of all types.
5 -15
Commercial
Sensors used in commercial applications include a broad
range of product categories. Vast arrays of sensors are being
installed to provide the input necessary to add intelligence to
management of our homes, offices, factories and streets.
Smart utility meters are able to track and report energy
consumption which can result in changes that conserve
energy and reduce cost.
Sensors located throughout electric, gas, oil and water

distribution systems enable “smart” utilities that are more
efficient and able to make instantaneous adjustments based
on demand and system failures.
Security cameras commonly deployed in commercial

businesses are now being supplemented by a new network of
video cameras that track all automotive and pedestrian activity
on our urban streets. Advanced systems generate high
resolution data that can be compared with a database to
identify specific individuals. Data generated by sensors built
into vehicles combined with video records of a crash allow
quick identification of the driver at fault.
Using networks of low-cost sensors connected to the Internet

and computation locally as well as in the cloud, cities are
getting access to analytical data, never before available.
Sensors now being deployed are measuring levels of air and
water pollution as well as the health of utilities, to signal the need for maintenance before costly failure.
The ability to identify the location of individuals making 911 calls via smartphone triangulation is
becoming increasing common. Crime has been reduced in neighborhoods where a network of
microphones are able to pinpoint the source of gunshots prompting immediate police response.
Advanced license plate recognition systems can be used to identify and trace stolen vehicles, recognize
repeat customers to support loyalty programs, detect non-permit holders in private parking lots and
improve security by highlighting problematic vehicles. These systems use high-resolution CCD and
CMOS image sensors to produce images of up to 10 plates per camera frame which are time stamped
with the GPS location of the vehicle.
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Retail stores and warehouses have used RFID tags

and readers for years to manage inventory as well as
reduce theft. Very low cost thin film smart labels
that feature an integrated temperature sensor are
manufactured using simple printing technology.
Some of these film-based environmental monitors

are perfect examples of sensor fusion as they may
incorporate a sensor, microcontroller, Bluetooth or
Wi-Fi radio, battery and antenna. Sensor modules

have been developed that use tiny embedded
batteries or simply harvest necessary energy from
ambient RF fields.
A new wave of video sensors is extending their

data collection capability to provide a much more
detailed profile of retail customers.
RetailNext installs sensors throughout a retail store that are

capable of recognizing and recording customer activity
including how many people walk past the store, how many
come in, their gender, approximate age, amount of time
spent in the store, where they go in the store, what
merchandise they are examining, degree of interaction with
sales associates, use of fitting rooms, wait time at checkout
and ultimately if and what they bought. A network of ceiling
mounted sensors utilize the power of multiple video sensors
as well as face recognition software to gather, analyze and
report this amazing amount of customer data.
Voice recognition and voice control technologies are continuing to improve raising the potential for
capacitive and piezoelectric MEMs microphones. Hands-free control applications in smartphones,
vehicles, games, and wearables are gaining interest.
Unlike capacitive microphones, piezoelectric devices are

resistant to moisture and dust, and can be directly
attached to a surface to create a contact microphone.
They can even be immersed in a liquid to measure levels as
well as sound waves. Piezoelectric microphones can be
made small enough to fit the tiny spaces available in
mobile devices. A piezoelectric microphone can also be
made to serve as a buzzer or audio speaker.
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Personal digital assistants such as Alexa use four microphones not only to provide clearer pick-up of
voice commands, but also to determine the location of the person speaking. The next generation of
personal assistants will allow fluid conversation with access to the entire store of information on the
Internet.
The agriculture industry has become highly dependent on fully automated systems that utilize sensors
to detect and measure everything from tractor location to moisture content of harvested corn. Tractors
use differentiated GPS signaling to identify portions of a field that exhibit different soil types allowing
customized application of irrigation, fertilizer and herbicides. Tractor automation has progressed to the
point that autonomous tractors plow plant and harvest fields without a driver.
Commercial drones studded with sensors now fly over fields capturing crop condition data and video.
Sensors have been developed that measure water quality, soil pH, soil moisture, overall plant health and
even crop ripeness. Sensors used in agricultural applications must be ruggedized and environmentally
sealed to resist corrosive materials, moisture and temperature extremes. A large farm may contain
hundreds of low-cost networked wireless sensors to provide real-time crop data.
Insuring that sensitive goods in transit are not exposed to

excessive cold or heat makes data logging tags essential,
especially in shipments of food and pharmaceuticals. The
TagTemp temperature logger can record over 4000 points at
intervals of every five minutes to every two hours, with a
battery life of up to 400 days. This devices uses a near field
communication link to an applicaion installed on a smart
phone to configure and download data.
Alternative energy production is growing at an estimated

compound annual growth rate (CAGR) of over 25%, and
has spawned applications for sensors in new sources of
power including wind turbine generators. Critical
functions such as gearbox, and generator coolant
temperature and flow rates, equipment temperature,
wind speed and direction depend on sensor input.
Proactive equipment maintenance programs rely on dust
5 -18
sensors to predict the accumulation of gunk on gears and bearings as well as vibration sensors that can
pinpoint failing components. Ambient temperature and humidity data is used to shut down the turbine
if ice is beginning to build up on the blades. Lightning sensors provide wind farm operators information
on the time of strike, location, intensity and polarity. Recently introduced systems can even identify
which specific blade was hit. Acoustic sensors mounted on the ground near wind turbines are used to
quantify the annoying sound created by these large machines. Since sensors serve such a critical role in
the operation and protection of expensive equipment, they must be accurate and rugged to survive
harsh outdoor environments and designed for a long service life.
Utility suppliers are encouraging their customers to

improve energy efficiency of their homes, by offering
free efficiency evaluations and recommendations. It
is often more cost effective to reduce demand than
increase capacity. One of the most significant
sources of lost heat is through poor or inadequate
insulation. The type and depth of existing insulation
can be measured, but one of the most effective ways
to demonstrate heat loss is through thermal analysis.
Consultants use infrared thermographic cameras to
graphically demonstrate thermal leaks in a home.
Non-contact pyrometers can measure the temperature of most surfaces

that range from below zero to over 1000 degrees F with +/- 1 degree
accuracy. They are particularly useful in measuring materials that are
moving or hazardous. The temperature of live high-voltage circuits can be
safely measured using these devices
Film-based sensors are attractive as they consume

little space and roll-to-roll production results in very
low cost products.
Conventional date codes on packaged food is one

way to determine freshness, but sensors now in
development will result in “smart” packaging that
immediately detects the byproducts of spoiling food.
Research at the University of Sidney has resulted in printable conductive ink food sensors that detect
gases produced by bacteria. The result will give consumers the ability to detect spoilage, reduce food
wastage and gastric distress.
5 -19
Extremely sensitive gas sensors have been designed specifically to

assist in rescue operations. These tiny sensors detect traces of
isoprene, ammonia and acetone, all of which are metabolic products
released in low concentrations through our skin and breath.
Incorporated in small hand-held devices, these low cost sensors can
replace trained dogs and can be provided to each rescuer, saving
critical time.
Amazon has successfully disrupted the

retail world with their on-line virtual
shopping cart and rapid delivery business
model. Their latest assault on
conventional stores came in the form of a
cashless automated convenience store that
allows shoppers to select items and walk
out without stopping at a checkout
counter.
The ceiling of this experimental “GO” shop

is studded with video and depth
perception cameras to track every
customer movement from multiple angles.
Weight sensors in the shelves also

report when precisely weighed items
are selected. The system is able to
detect products that are selected and
later returned to the shelves.
Customers enter the store using the

Amazon Go application on their
smartphone and begin shopping.
When done, they simply walk out
avoiding a wait at the checkout lane.
Charges appear on their Amazon
account a few days later.
5 -20
Serious, probably off-site computing power

and unique algorithms assemble the streams
of incoming data from hundreds of sensors to
create a real-time picture of who is buying
what with 99% accuracy, and also minimizing
potential shoplifting. The measurement and
tracking technologies Amazon utilizes in the
GO store are similar to those developed for
autonomous transportation and include
computer vision, sensor fusion, and deep
learning.
The cost effectiveness of the GO convenience
store may not inspire competition yet, but is
an excellent example of what innovative data
collection by an array of advanced sensors is
capable of achieving.
Tasks that appear simple can be a challenge when

relying on our human senses. The ability to precisely
match paint colors for instance can now be
automated using the NIX color sensor. This pocket-
sized device records the color of a scanned surface
for matching to imported color libraries.
Air quality is an ongoing issue especially in high-

density urban areas. IBM Research is exploring
the use of silicon photonics to develop sensors
that can instantly detect environmental
pollutants. Networks of miniature silicon chip
spectrometers located near potential sources of
pollution may be able to detect contaminants in
the air the moment they occur.
5 -21
The city of London England has begun a trial installation of an air sensor network at 100 locations in an
effort to identify the source of pollution. The program could be expanded to thousands of additional
fixed and mobile sites. Data resulting from this trial program will be shared with other cities working to
address climate change.
The program could be expanded into a network of 20 cities.
5 -22
Automotive
Development of vehicles powered by an internal
combustion engine burning gasoline began over 130
years ago. Over the intervening years, the automobile
has undergone a relatively slow but continuous process
of improvement in terms of power, efficiency, reliability,
safety, range, and comfort, but the basic elements of
cars built in the 1930’s are very similar to what is being
offered today.
Over the past 10 years, the automobile has experienced a dramatic conversion to digital technology.
Functions that were traditionally achieved via mechanical actuators have transitioned to digital control.
New functions such as combustion management and collision avoidance that can detect and respond to
instantaneous events can only be realized via electronic systems. Mechanical systems have been
replaced with electronic digital management in a wide variety of performance, safety, entertainment,
communication and comfort features.
The list of functions now under electronic management continues to grow with each new model year.
5 -23
The result of this digital transition is that autos, trucks and even heavy equipment have become a series
of rolling computers. Data flows from a network of electronic sensors that have been designed
specifically for the challenging physical and economic demands of automotive applications.
These sensors have been responsible for the vast improvements in fuel economy, emission reduction,
safety and comfort that cars now offer. As with all automotive components electronic sensors must be
capable of surviving a five to ten year service life in an environment of extreme temperature swings,
with exposure to dust, moisture, lubricants, shock and vibration. Many of these sensors perform in
critical passenger safety functions making high-reliability an absolute requirement.
The transportation industry is now in the midst of the evolution toward replacing the driver with
electronic control and navigation.
The Society of Automotive Engineers (SAE) has defined five levels of automotive automation.
The first 110 years of cars have been spent at level 0 with the driver in full control.
Level one defined as driver assistance introduced several safety features such as automated emergency
braking, and cruise control.
Level two combined automation of several functions reduces driver fatigue by taking over several
5 -24
functions such as active cruise control which manages speed control and safe spacing between cars in
non-emergency situations. This is often defined as augmented or partial automation.
Level three further reduces driver involvement for normal operation with limited self-driving. Functions
such as driving in a defined lane and automated parking still require the driver to be the primary source
of control. Vehicles with conditional automation are now available in selected models.
Level four: High automation vehicles in mode specific parameters with or without human intervention.
Level five: Full automation allows a vehicle to operate in full time automated mode in all dynamic
driving environments. This is the ultimate objective of the autonomous vehicle development effort.
Many vehicles now on the market offer level three advanced driver assistance systems (ADAS); a
technology that is continuing to migrate down from premium to standard models.
A network of sensors both internal and external provides these level 3 driver assistance functions.
The next leap in automotive technology will shift the industry away from the traditional internal
combustion engine to a combination of next generation hybrid and all electric vehicles. These cars will
integrate advanced machine vision, on-board computation, IoT connectivity, GPS navigation, and
advanced battery chemistry. All of these will be managed by sophisticated software and algorithms that
will require data generated by an array of new sensors.
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The movement toward autonomous transportation will completely challenge the current paradigm of
personal transportation, and will also create extensive opportunities for manufacturers of automotive
sensors.
Autonomous cars will require real time 360° situational awareness of everything surrounding the
moving vehicle out to a distance of several hundred feet. The use of radar, far infrared and ultrasonic
detectors that support many of the driver assist functions offered today will be supplemented with Light
Detection and Ranging, (LIDAR) sensors that can “see” through adverse conditions of fog, rain and snow.
LIDAR sensors are

based on the same
reflective principals
of conventional
radar except they
use rapid rotating
pulses of laser
beams instead of
radio frequency
energy.
5 -26
The result is a three

dimensional video
stream of objects
including people in
the vicinity of the
vehicle. Advanced
algorithms are able
to interpret these
images, identify
objects and generate
appropriate
responses.
Autonomous vehicles now in test mode

feature LIDAR sensors mounted on the roof.
Manufacturers of LIDAR sensors face multiple
challenges in increasing accuracy while
reducing the size and cost of these precision
devices.
The large volleyball size LIDAR sensors now in use are

undergoing the process of downsizing to allow integration
within the styling of the car.
A recent fatal accident in Phoenix Arizona involving an

autonomous UBER car and a pedestrian highlights the
imperative of sensor accuracy as well as software
interpretation.
5 -27
System designers of fully autonomous vehicles anticipate that “fail-safe” navigation will require
coordination of multiple LIDAR as well as RF and ultrasonic sensors.
In addition ultrasonic sensors will report proximity to nearby objects. On-board video cameras will
provide signage and road striping input that ultimately generates signals to steering, acceleration and
braking decisions. GPS signal data will be used to locate exact position of the vehicle as well as
navigation data. In order to achieve this increasing degree of automation, fully autonomous vehicles will
utilize multiple high-speed internal networks that will coordinate hundreds of sensor inputs for
processing and actuation.
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The ability of a vehicle to safely navigate within a swarm of other vehicles in all types of weather
conditions requires constant 360° situational awareness.
By 2022, many production cars are

expected to be capable of level 5
performance which will also include direct
communication with nearby cars, as well
as traffic control signals. Traffic flow will
be managed based on moving the most
vehicles rather than a fixed timer. Existing
traffic monitoring and control devices such
as stop lights and signs could become
obsolete as autonomous vehicles have
access to highly detailed highway data to
manage speed, an array of sensors to
adapt to road conditions, and vehicle-to
vehicle communication to allow negotiation for right of way.
A result of this major transportation revolution will be an immense increase in demand for high-
performance sensors and associated interconnects. Market analysts have estimated that vehicles that
incorporate partial automation adds between $100 to $150 of semiconductor content in addition to the
current $330 of electronics in cars on the road today. Full level five autonomy will add an additional
$550 to the cost of the car. Current cars may have as many as 170 sensors, 90 electronic control units
and 150 actuators. One forecast anticipates that automotive manufacturers will be buying more than 10
billon sensors by 2020. At this point, the automotive market is anticipated to be one of the most rapidly
expanding sensor opportunities over at least the next 10 years; an opportunity that has been noticed
by many component suppliers including connector manufacturers.
The race to develop cost-effective, high-reliability automotive digital components including short
response time and robust sensors is already well underway.
A thermal far infrared thermal camera by Adasky features

built-in machine vision algorithms to provide object detection
and scene analysis. Using their heat signature, pedestrians can
be detected at a range of several hundred meters.
Electric vehicles generate little sound posing a danger to

pedestrians and bikers. The developmental Kia Niro EV
features a pedestrian warning system that uses front-view
cameras and object recognition technology to identify people
in the path of the car and emit an audible alert. The Niro also utilizes facial recognition and voice
command to “log in” which automatically adjusts settings to personal preferences.
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Designing sensitive MEMS sensors for rugged automotive

under-the-hood applications is a major challenge. Sensor
output must be stable under wide swings of temperature and
vibration, and often must include provisions for noise
filtering. Melexis has introduced a pressure sensor that
stands up to these environments. In addition to the sensor,
the 4X5 mm module integrates analog front-end circuitry, a
16 bit microprocessor, voltage regulators and a transmission
driver. Initial applications for this sensor include
measurement of manifold air pressure.
The frustration of searching for an open

parking lot space is being addressed by a Bosch
system that places low-profile sensors in each
parking space. These sensing pucks are
powered by a battery with an expected life of
up to 7 years. The sensors detect the presence
of a car and report to a central server. A
continuously updated map showing open
spaces is displayed on the associated
smartphone application.
Sensors related to automotive applications offer huge sales growth potential over at least the next 10
years. Forecasts call for the many types of automotive sensors to reach $36.4 billion by 2023 with a
CAGR of 6.71%. These numbers are attracting a host of suppliers including selected connector
manufactures.
5 -30
Healthcare / Biomedical
Medical equipment that
relies on sensor
technology represents
some of the most exciting
product segments
available today. Flexible
and wearable sensors are
opening entirely new
applications including
artificial electronic skin,
physiological monitoring,
therapeutic and drug
delivery capabilities.
A wide variety of sensors

including temperature,
pressure, vacuum,
dissolved gas, radiation, optical, flow rate and video play key roles in medical diagnostic and therapeutic
equipment. Tiny electric signals in our brain and heart can be detected to provide invaluable insight on
the condition of these organs.
Sensors are used in many medical equipment applications including:
• Respiratory devices
• Sleep diagnostic devices
• Organ performance measurement
• Anesthetic administration and monitoring
• Dialysis
• Infusion
• Oxygen concentration and administration
• Vacuum pumps
• Videoscopic examination
• Body fluid analysis
• Pulse oximeter measurement
• X-ray machines
• Computer tomography
Medical equipment typically used in a hospital or clinic must be designed for accuracy as the
information produced may be used to make life or death decisions. It must also perform flawlessly for
years while being exposed to aggressive cleaning, UV, shock, sweat, and continuous harsh sterilization
processes. Medical equipment must be approved by the FDA to insure it poses no danger to the patient.
As a result, medical devices have tended to be expensive, and designed for use by trained technicians.
5 -31
The evolution of consumer medical and wearable devices along with increased emphasis on better
preventive care has begun to change this paradigm. Skyrocketing costs of in-patient care is spurring
efforts to replace hospital stays with in-home alternatives. Advances in semiconductor sensor
fabrication technology have enabled devices that are smaller, less costly and feature the ability to
measure multiple parameters. A combination of the IoT, improved battery life, miniaturized low power
wireless transmission, sophisticated software and algorithms along with a new generation of low-cost
“smart” sensors is changing the way health services are being delivered.
Skin, being our largest organ has become

an attractive, non-invasive gateway to
sense and capture bio-signals generated
by the body. At the same time the fusion
of advanced sensors, microprocessors
and wireless communication chips are
rapidly expanding the ability to develop
cost-effective wearable health monitoring
systems. These low-power devices
establish “body networks” that can be
worn for days while communicating vital
biometric data in real time.
Early wearables were designed around

traditional electronic device form factors
which were flat, rigid and fragile. The
materials used were not compatible with
the soft curved and flexing human body.
These devices were often unable to maintain intimate contact with the skin for long periods of time
making the resulting data questionable. The introduction of new, highly supple materials that conform
to human contours as well as being hypoallergenic has increased interest in wearable medical devices of
all types. Conditions that a few years ago required an extended stay in a hospital now can be monitored
more accurately over weeks from home.
One class of wearable devices intended for

professional use includes a wireless patch that
can be immediately applied to a patient’s chest
when they arrive at a hospital emergency
room. Rather than spend time attaching
individual corded sensors, the patch uses a
series of integrated sensors to immediately
begin monitoring temperature, pulse rate,
blood pressure, blood oxygen levels, cardiac
rhythm and electrical activity. Data is
wirelessly transmitted to a server for
presentation to doctors.
5 -32
Acoustic monitors use an adhesive neck

sensor, which is a specialized microphone to
detect the sounds generated by respiration.
The respiratory rate is an indirect measure of
CO2 retention particularly important in post
operative patients.
Using similar technology is the AbStats, which

is a disposable plastic listening device that
attaches to the abdomen of a patient that has
undergone surgery. Sensing and analyzing
gastric sounds help doctors definitively
determine which post-operative patients
should be fed and which should not. Use of
this data may improve outcomes, decrease
healthcare costs and shorten hospital stays,
according to a UCLA study.
Sensors that measure the amount of oxygenated

hemoglobin in the blood are commonly supplied as
molded cable assemblies with connectors designed
to mate with specific brands of display and recording
equipment.
5 -33
Wearable sensors that are able to wirelessly transmit

health information over periods of days or weeks are
a particularly attractive product segment. They must
be comfortable, user friendly, able to operate in a
hospital or home environment, offer long battery life
and be reasonably priced.
Elastic chest bands are giving way to soft, adhesively

attached modules or patches that require no user
intervention. Depending on the application, battery
life can be extended by choosing to transmit data
intermittently rather than continuously. Disposable
clinical-grade biosensor patches free patients from
wires and cables which improves their mobility while
providing 24/7 monitoring. These patches feature integrated sensor signal acquisition, data processing,
wireless transmission and power management functions. Wireless connection range is up to 25 meters.
Flexible film or elastic materials are ideal substrates on which to build wearable sensors. Their light
weight and flexibility can increase comfort and make them nearly unnoticeable. New polyamide
materials and conductive inks that adhere to stretchable surfaces are opening entirely new
opportunities for medical monitoring devices.
Complete lab-on-chip devices are capable of

analyzing body sweat for specific biomarkers that can
indicate health and wellness. The chip uses capillary
action to pump tiny amounts of sweat into the
device. Four different silicon sensors inside the
module are only 20 nanometers thick making them
extremely sensitive. Work to incorporate this
technology into a bracelet is under way.
A printable film glucose monitor patch may

also eliminate daily finger needle pricks
required by people afflicted with diabetes.
Developed by scientists at the University of
Bath in the UK, the graphene-based device
is applied to the skin without piercing its
surface. It utilizes an array of miniature
sensors, which apply a small electric current
to draw glucose out from individual hair
follicles, where it is measured and reported
on a smartphone application. Still in
development, a commercialized patch could
generate alerts if glucose levels exceed defined limits.
5 -34
Additional film-based sensors have

been designed for implanting directly
on or into the body. They may
incorporate multiple sensors,
wireless communication and
antenna. They can are powered by
ambient RF energy or RFID.
Additional research into the potential of flexible “digital tattoos” that will
result in wearable electronic sensors that monitor biometric data while
being nearly unnoticeable to the user. Some of these patches will be
fabricated using carbon nanotubes materials for increased sensitivity and
low power consumption.
Failure to take prescribed medication has been a

persistent problem. Patients living at home who have
mobility problems, and particularly those suffering
from Alzheimers often have a hard time
remembering which medication to take and when.
Solutions have included pill bottles that are
programmed with the schedule and sends alerts to a
smart phone when the medication is to be taken.
Visual, audio, text messages and e-mail alerts
continue until a button on the bottle cap is pressed.
Engineers have been working on a more advanced
solution. Their smart bottle sends alerts to both the
patient and caregiver when a dose is due, but also
alerts the patient to where the pill bottle is located.
Sensors in the cap detect when the bottle has been
moved to record the time of dosage.
5 -35
A Spanish research team from Valencia Polytechnic University has developed an electronic “nose” that is
able to differentiate between Crohn’s disease and colitis by sensing volatile organic compounds found in
feces. The severity of the disease can also be calculated based on this analysis. Additional applications
for this sniffing technology include measuring microbial contamination of water as well as assessing the
ripeness of fruit.
Microminiature sensors offer the ability to create

implantable sensors that continuously measure a
specific property over longer periods of time. An
injectable chip sensor that is capable of monitoring
blood alcohol levels is under development for use
with people in substance abuse treatment programs.
The chip integrates sensors for alcohol, pH levels and
background noise. Data is transmitted to a
smartwatch. Power to operate the chip is harvested
from RF energy generated by the watch.
Military leaders want to be constantly aware of the health of their soldiers, who are exposed to a wide
range of environments and threats. Implantable monitors that track blood pressure, heart / respiration
rate, temperature as well as consciousness could allow commanders to decide if troops can be deployed
or not. Streams of real time Health data on each solder could be relayed by satellite to remote medical
facilities for review. Such a system would be particularly valuable when a soldier is injured and needs
immediate medical care.
All devices designed for medical applications face a variety of daunting technical and economic
challenges. Depending on the intended application, the product may be limited to relatively low
production volume, while demanding high development and FDA approval costs which may extend the
development cycle into years.
The good news is that our ageing population combined with greater awareness of physical fitness will
guarantee exceptional business opportunities for sensors that support applications in health and
wellness.
5 -36
Smartphones
Mobile communication devices with integrated computing
capabilities have become the essential device for connecting
with people, information and things. Over the years since it
was first introduced in 1992, smartphones have continued on
a remarkable path to increased utility and have become an
essential tool of daily life for people around the globe.
Smartphones can be considered a mobile general purpose

computer equipped with an array of internal sensors. Their
design enables extreme application flexibility and adaptability
to a ever-expanding range of uses. Users have access to over
three million downloadable applications, many of which are
free, that enable a smartphone to deliver a universe of
information entertainment as well as provide multiple forms
of audio, video and text communication. Incredible levels of
internal computing power and data storage is now being
enhanced by connection to cloud resources. The emerging
Internet of Things is putting the smartphone at the focal
point of remote monitoring and control of both external and
internal devices ranging from security cameras to the hue of interior lighting.
Depending on the age

and model of the device,
smartphones may
incorporate up to 14
sensors.
The IphoneX is reported

to include a 3D sensing
module used to deliver
face recognition
capabilities.
Creative application of these sensors is allowing the smartphone to become a central hub for medical
diagnostic and monitoring functions. New applications and plug-in accessories are enabling
smartphones to become a form of “doc in your pocket”, and may someday be capable of performing a
variety of basic lab tests to diagnose a wide variety of medical ills.
5 -37
The high-resolution camera built into

standard smart phones can be used to take
detailed images of the eye and used for
remote diagnosis t he degree of vision loss.
Advanced applications are able to analyze
subtle changes in the whites of the eye to
diagnose multiple medical problems.
The Kardia device from AliveCor allows a user to simply

place a few fingers on this smartphone accessory for 30
seconds to receive a medical-grade EKG on the phones
display.
Devices now in development use light and spectral analyses

to do many of the most common laboratory tests that
require a blood draw today.
A pulse oximeter that measures blood oxygen levels plugs

into the iPhone audio jack. The associated application
displays the results on the phone screen. This data is easily
sent to a doctor or caregiver via e-mail.
FotoFinder Systems GmbH a manufacturer of digital

imaging products, recently released a unique device that
docks with an iPhone to turn it into a handheld digital
dermatoscope for performing skin examinations.
5 -38
Smartphones are also being used to collect data from industrial sensors for monitoring and analyzing
and adjusting production control systems.
The Sensorex SAM-1 Smart Aqua Meter is compatible

with Android devices as well as Apple iPhones and
iPads. It is used for laboratory and field monitoring of
water quality including pH, ORP, conductivity and
temperature.
A smart Geiger counter detects and measures nuclear

radiation and X-rays and can act as a personal dosimeter.
The sensor simply plugs into the smartphone audio jack
and sells on Amazon for $33.
By plugging in a Seek thermal smartphone infrared camera module, one can

inexpensively scan surfaces to produce close to military or industrial-grade
thermal images. The device can accurately display a range of temperatures from
-40° Celsius (-40° Fahrenheit) up to 330° C (626° F). The half-once module
communicates to the smart phone via the phone Lightning connector port.
Many more commercial and industrial applications are taking advantage of the
versatility of the smartphone to monitor measure and manage manufacturing
processes.
5 -39
Military / Aerospace
Military and aerospace equipment has long relied on a wide range of precision sensors that can target
weapons, detect enemy fire, sense poisonous gasses, monitor aircraft engine conditions, provide night
vision, and deliver accurate direction and locational data. Sensors are the eyes and ears of a host of
modern surveillance, battlefield vision, weapon control, and equipment monitoring devices. These
mission-critical components are often deployed in the most severe environments imaginable in terms of
temperature extremes, mechanical shock & vibration, EMI, exposure to corrosive liquids as well as a
laundry list of contaminants.
Sensors provide the input

necessary to generate
essential situational
awareness as well as report
local environmental
conditions.
Accurate sensors are used in

systems that identify enemy
locations, track troop
movements, target
weapons, guide weapons to
the target and later assess
the effectiveness of the
strike.
Military/aerospace sensors are designed to perform

flawlessly for years, which often require packaging
sensors in extremely ruggedized enclosures that
protect the sensitive sensor from damage.
5 -40
A day and night fire control system that uses

multiple sensors for target acquisition, aiming
and firing artillery regardless of weather
conditions is an example of the hardened
packaging of field deployed sensors.
Sensors in this class may utilize state of the art technology to stay one jump ahead of the enemy.
Equipment design and development cycles may be require years of research and qualification. Since
these devices are custom designed specifically for military or avionic applications, production volumes
are comparatively low, making component and unit costs extremely high.
Sensors are being deployed in just about every type of new mil/aero hardware.
Drones both remote controlled and

autonomous are being increasingly deployed
in surveillance and attack missions.
In addition to navigation aids that use input

from a full complement of accelerometers,
gyroscopes, three axis inclinometers,
temperature, pressure and GPS sensors, high-
resolution pod-mounted visible light and
infrared sensors allow accurate navigation
and targeting.
BAE Systems has been developing the concept of a “smart skin” for military aircraft. The intent is to
cover the fuselage of military aircraft with thousands of micro sensors that could pinpoint areas of
stress, heat or damage. Accumulated data would be continuously analyzed and out-of-norm conditions
reported the crew.
In an effort to provide better protection as well as intelligence harvesting capabilities, soldiers are now
being equipped with sensors integrated into accessories and wearables that were originally developed
for consumers.
5 -41
Robotic battlefield “pack mules” are designed to haul

materials and even wounded soldiers over uneven
terrine. The newest class of these machines is able to
climb up steep slopes, travel long distances, run
through a forest and even right themselves if tipped
over. The on-board electronics relies on a network
of sensors that coordinate motion, identify obstacles,
maintain balance as well as determine location.
The defense Advanced Research Projects Agency (DARPA) has revealed a program titled Advanced Plant
Technologies. Recognizing that plants respond to basic stimuli such as light and water, perhaps they can
be used to identify threats. The objective is to genetically modify select plant types so that the plant
responds in a measurable way to specific stimuli such as chemical, biological, radiological or nuclear
materials. The plant essentially becomes an organic sensor, changes in which can be detected by a
portable analyzing device.
5 -42
Chapter 6
Chapter 6 Sensor Industry Leaders

Introduction
Manufacturers of electronic sensors are a

classic example of a large and diverse group
with suppliers located across the globe. A
recent search for sensor manufacturers on
ThomasNet.com resulted in 2,674 hits.
Suppliers are scattered in nearly every
country with major manufacturers located in
Asia, Europe as well as the United States.
Similar to electronic connectors, identifying

which manufacturers of sensors are the
largest is very much dependent on the
market segment they serve, region of the
world, type of sensors sold and total sales.
Some manufacturers make sensors their only product offering while sensors may be one part of a broad,
often related list of components and assemblies.
The industry is also segmented by suppliers that offer sensors based on more conventional assembly
techniques while others have focused on sensors that utilize newer microelectromechanical systems
(MEMS) technology. Some suppliers offer extensive lines of discrete chip-level sensors, while others
provide multiple sensors integrated into a standard or custom package. Sensor manufacturers that
support applications in markets that require a high degree of customization such as aerospace and
medical, design sensors that are highly application specific, while others sell an extensive line of general
purpose and cataloged sensors.
Finally, a subcategory includes semiconductor packagers of electronic assemblies that participate in the
sensor market to the extent that they offer wirebonding, metallic lid, molded cavity, hermetic sealing,
and final test resources. They may be a subcontractor to a larger manufacturer of discrete sensors or
may acquire sensors and then apply their packaging expertise to produce a sensor assembly for an end
customer.
The result is a highly fractured industry with thousands of participants. Very large global suppliers may
offer an extensive line of sensors that are used in a broad range of markets, while very small players may
manufacture a few highly specialized sensors and/or assemblies.
The much anticipated increase in demand for sensors to address extremely high volume applications in
the Internet of Things, Industrial Internet of Things and autonomous transportation markets is driving
industry consolidation and providing a strong incentive for manufacturers to either increase their
current product offerings or acquire smaller players in order to become a participant. Given the large
number of current players, this process of mergers and acquisitions will likely continue and even
accelerate over the next five years. Large component manufacturers such as Amphenol, TE
6 -1
Connectivity, and TDK have been actively acquiring sensor resources through the acquisition of smaller
competitors.
The following pages are not intended to be an all-inclusive list of sensor manufacturers, but are offered
only to provide a representative overview of major industry participants, types of sensors they offer and
the primary markets on which they focus.
Large Sensor Industry Leaders

Some of the largest global manufacturers of electronic sensors based on breadth of products as well as
total sales include:
• Robert Bosch GmbH

• Texas Instruments
• STMicroelectronics
• NXP Semiconductors N.V.
• Honeywell
• Infineon Technologies
These manufacturers offer extensive lines of sensors used in a broad range of markets including
automotive, medical, IoT, industrial, military or consumer.
Sensors targeting IoT applications have become a new rapidly expanding market segment over the past
few years. In some cases a manufacturer’s line card of sensors may emphasize one particular
application segment such as automotive or industrial but also include more general purpose sensors.
They may also specialize in a particular sensor technology such as MEMS. Except for Infineon, sensors
are one aspect of a much broader product line of related products offered by these suppliers.
Another segment of suppliers are large companies such as Qualcomm that make a very narrow line of
sensors specifically designed to support their target market. Recognized widely as a primary supplier of
semiconductors designed for mobile devices, they also offer ultrasonic biometric fingerprint sensors that
offer greater sensitivity than traditional capacitance sensors. They also can be used to sense blood flow
and heart rate, as well as recognize gestures for navigation.
At the other end of the sensor supplier spectrum are companies

such as SPEC Sensors whose product line focuses exclusively on
gas sensors.
6 -2
Robert Bosch GmbH / Bosch Sensortec

Bosch is a globally recognized leader in transportation
related products. They offer full design, manufacture, and
application support including software platforms to simplify
the design-in process. Much of their sensor product line is
designed for applications in the automotive segment, but has been expanded to applications well
beyond mobility. The Bosch Sensortec group was established in 1995 and was charted to focus on more
consumer and commercial product sensor applications utilizing MEMS technology.
Devices are available in standard PCB mounted packages

as well as application-specific configurations.
Bosch manufactures devices in three general categories: motion, environmental and optical sensing.
The motion segment includes an extensive line of accelerometers, 3- axis gyroscopes, geomagnetic
sensors, inertial sensors, 9-axis absolute orientation sensors, pressure sensors, smart sensor hubs as
well as integrated sensor fusion sensors. Products in the environmental segment include pressure
sensors, and integrated sensors for the wearable and IoT markets. The new optical category includes a
sensor for use in a laser scanning projector.
Bosch is a full service sensor supplier. In addition to sensing hardware, Bosch offers a sensor software
platform that speeds implementation of their devices.
6 -3
Texas Instruments
Leveraging its extensive expertise in semiconductor chip
design and manufacturing, TI has assembled an extensive line
of electronic sensors. The vast majority of their sensors are in standard PCB mount leaded packages or
in surface mount leaded and leadless configurations.
TI sensors address multiple markets including automotive, industrial, personal electronics and enterprise
systems. Sensor types offered include temperature, mm wave, humidity, optical, magnetic, photodiode,
capacitive, inductive, ultrasonic, gas, and chemical. Sensors designed for harsh environment
transportation applications are rated automotive grade. Sensors are available with either analog or
digital outputs.
In order to support their sensing products, TI

offers evaluation boards as well as reference
designs to assist in verifying performance as
well as speed implementation.
6 -4
STMicroelectronics
STMicroelectronics is a broadly diversified manufacturer of
semiconductor devices that includes aerospace/defense
products, amplifiers, audio IC, automotive ICs,
microcontrollers, data converters, diodes and rectifiers, EMI
filters, imaging and photonic devices, memory,
microcontroller, NFC, power modules, RF transistors, thyristors, and wireless connectivity as well as
MEMS sensors.
Target applications range from low cost

IoT, to precision Industry 4.0 devices.
They offer a full line of gyroscopes,

compasses, humidity, temperature,
pressure, touch, UV index, and
proximity sensors along with MEMS
microphones and inertial modules.
Their ability to combine multiple

sensors with a microprocessor, voltage
regulator and RF transmission highlights
their value added resources.
iNEMO inertial modules integrate complementary

types of sensors to offer more compact, robust, and
easy-to-assemble solutions compared to discrete
sensors. This system-in-package (SIP) combines an
accelerometer, gyroscope, and magnetometer into
one monolithic package.
6 -5
NXP Semiconductors N.V.

Based in the Netherlands, NXP is a global manufacturer of a
broad range of semiconductors including an extensive line of
sensors.
NXP manufactures a full line of sensors specifically designed for automotive applications, as well as 1, 2,
3, and 6 axis accelerometers for the IoT.
They also offer multiple variations

of gyroscopes, and magnetic
sensors.
Additional sensors used in automotive applications include

angular position sensors, temperature, voltage, and rotational
speed sensors.
A tire pressure monitoring system integrates a pressure

sensor, an 8-bit microcontroller, accelerometer and RF
transmitter in a ruggedized package.
In order to simplify and speed the design-in process,

NXP offers their customers a sensor toolbox which
includes evaluation boards, demonstration kits, sensing
software development tools, as well as visualization
software.
6 -6
Honeywell International
Honeywell, recognized as a manufacturer of home comfort
devices is actually a large multinational conglomerate that
manufactures a wide variety of commercial and consumer
products.
The Honeywell Sensing and Control business unit produces a full array of heavy duty sensors primarily
used in industrial and commercial applications.
Their product mix includes sensors for air flow, electric

current, force, humidity, temperature, Hall-effect angle,
position and speed sensing, infrared liquid level and particle
sensors, pressure, and non-contact rotation.
Many of their sensor products are used in the HVAC industry.
Honeywell sensors may be

leaded or provided with a pluggable interface.
They also manufacture a broad line of printed circuit

board mounted low-pressure sensors.
Test and evaluation boards as well as software are also

available.
6 -7
Infineon Technologies AG
Infineon Technologies is a large German semiconductor
manufacturer that was spun-off from Siemens AG in 1999.
They manufacture devices that go into a wide range of

applications including, industrial automation, consumer,
building automation, health and fitness, automotive, motor
control, robotics, and alternative energy systems. Their sensor product lines are focused on automotive,
industrial, and consumer applications. Infineon enjoys a large market share in automotive applications
such as side air-bag, anti-lock brakes, wheel speed, and tire pressure sensors.
Sensor types include:
• Image and radar sensors

• Angle sensors
• Magnetic current sensors
• Speed sensors
• Barometric pressure sensors
The majority of Infineon sensors are packaged for surface mount

attachment to a PCB, but they also manufacture leaded sensors.
There are literally hundreds of medium and small manufacturers of electronic sensors that are located
around the world. Suppliers such as Sensata Technologies based in the United States offer a full line of
position, temperature, speed, force and pressure sensors as well as a solid state LIDAR system. TDK is a
major supplier of electronic components including temperature, pressure, angle, level, Hall-effect,
humidity, gear tooth, and AC current sensors as well as MEMS microphones. The industries these
companies serve range from aerospace to materials handling.
6 -8
Sensor Manufacturers by Application Segment

Many sensor manufacturers offer multiple sensor types that can be applied in a wide range of
applications. In other cases, a supplier may choose to support a specific industry segment with highly
application specific sensors. This is particularly true when an application segment exhibits highly specific
requirements such as:
Military / Aerospace: Extreme reliability in harsh environments with highly customized configurations.
A supplier must be very familiar with the environment that the sensor must operate in as well as
required product qualification processes. Sensors in this category may require suppliers to have access
to highly specialize test equipment to verify performance to specification. Mil/aero are classic low
volume/ high price components.
Medical sensors must be extremely reliable and often capable of withstanding multiple cleaning and/or
sterilizations possibly by untrained staff. The use of non-magnetic materials may be required.
Manufacturers must be knowledgeable regarding FDA restrictions and device approval processes. As
volume of wearable medical devices increases, the market will demand smaller, lighter, low power
sensors that are becoming more cost sensitive. Multi-sensor modules with wireless communication will
require RF expertise.
Applications in industrial control require components that are rugged enough to survive on the
production floor with added accuracy and performance reliability. Compatibility with standard network
protocols may also be required.
Consumer product applications typically require high volume / low cost manufacturing. Device
reliability and accuracy are balanced by the nature of the application.
For example, sensors used in automotive applications have encouraged many sensor manufactures to
add this class of device to their catalog. Some suppliers such as Delphi Automotive PLC, Robert Bosch
GmbH, and Denso have made automotive sensors their primary focus.
Expectations of growth in industrial control, factory automation and the anticipated Industry 4.0
applications have spawned sensor manufacturers such as Omega, Keyence, Turck and Siemens to
specialize with products that satisfy these unique requirements.
Suppliers such as First Sensor collaborate with medical product manufacturers to develop and
manufacture highly reliable sensors and custom sensor systems.
6 -9
Sensors, A Global Industry

Unlike some products that are manufactured almost exclusively in one region of the world, or even one
country, major concentrations of sensor manufacturers exist globally. Asia is estimated to have the
largest concentration of sensing device consumers, likely due to its proximity to large manufacturers of
consumer products, while sensor suppliers are distributed around the world.
The United States is home to very large sensor suppliers including Texas Instruments and Honeywell, but
the industry also includes major offshore players with full sensor product lines including:
• Robert Bosch GmbH – Germany

• STMicroelectronics – Switzerland
• Infineon Technologies – Germany
• TDK – Japan
• Melexis – Belgium
• Murata – Japan
• AMS – Austria
• Delphi Automotive – UK
• NXP - Dutch
Almost all of these sensor manufacturers except one offer sensors as one part of a larger overall product
mix. Texas Instruments for instance features an extensive assortment of semiconductor devices based
on their core manufacturing technology. Their chip products include amplifiers, audio, data converters,
DLP devices, logic chips, motor drivers, power management chip, embedded processors, digital signal
processors, RF and microwave chips as well as wireless connectivity modules.
Broadly diversified sensor manufacturer AMS is one of the few large suppliers that have chosen to focus
their product mix exclusively on sensors and directly related devices. They concentrate on designing
and manufacturing sensors intended for the consumer, Industrial and automotive markets, but also
have supplied optical sensors to the smartphone industry. They are actively forming partnerships with
other suppliers to develop technology for autonomous vehicles.
6 -10
Sensor Device Packagers

A subset of companies that participate in the electronic sensor industry are Outsourced Semiconductor
Assembly and Test (OSAT) contractors. These suppliers receive sensor wafers or chips from a foundry
and add wire / flip-chip bonding die-attach to a variety of substrates or lead frames, assemble multi-die
and stacked die assemblies, and install protective formed lid or molded cavity packaging in standard and
custom configurations.
There are roughly 100 OSATs active in this market, but the vast majority of the business is conducted
with a relatively few industry leaders including:
• Advanced Semiconductor Engineering (ASE Group)

• Amkor Technology
• JCET
• Silicon Precision Industries Co. Ltd.
Several additional providers include Unisem and EV Group.
The foundry can concentrate its resources on the complex design and extremely expensive production
equipment required to produce advanced semiconductor chips, leaving the packaging process to outside
sources.
OSATs also provide die probe and final assembly testing services to insure rated performance.
6 -11
OSATs have the experience and resources available to produce unique packaged assemblies.
Complex stacked die assemblies can combine sensors, microprocessor, and RF radio into a complete
system on package.
The sensor industry participants reviewed here comprise only a part of the overall $95 billion market for
electronic sensors.
6 -12
Chapter 7
Chapter 7 Sensor Industry Standards

Introduction
One would expect that a class of components that play such a critical
role in so many burgeoning technologies and applications would be
fully defined by multiple industry accepted standards. The existence
of a standard allows a design engineer to have confidence that a
particular component will perform to a defined minimum level of
performance within a range of environmental conditions, exhibit
consistent mechanical dimensions, and be compatible with other
standard components manufactured by multiple suppliers. Standardized parts speed the design-in
process minimizing time to market. Electronic sensors may be the exception to that rule.
Take for example sensors designed for automotive applications. A sensor , located in the passenger
cabin is exposed to a comparably benign environment. Temperatures could range from 130° F to below
zero but that is relatively benign compared to a sensor located under hood where temperature
extremes are much higher, while being exposed to moisture, dust, oil and vibration. Mission-critical
sensor applications such as air bag deployment and anti-lock brake systems directly impact passenger
safety and require a high degree of component reliability.
Component suppliers commonly use the phrase “automotive qualified” in their marketing material
inferring that the component has superior ratings that offer higher reliability and longer operating life
than a similar component not so designated. Also implied is that this extra level of quality justifies a
premium price. The reality is that there is no clear definition of what an automotive qualified sensor
actually means. It may have enhanced service parameters such as a wider operating temperature range
or be tolerant of higher voltage swings, but there is no comprehensive standard that defines what
extended performance automotive qualified parts deliver. The result may require verification testing
in order to verify performance in a specific automotive application. This process consumes time and
resources.
The issue of exactly how performance of a sensor is documented in the supplier’s specification was
taken up by IEEE four years ago. It was noticed that major sensor manufacturers were documenting
their products using different parameters making it nearly impossible for users to directly compare
performance. IEEE P2700 was released in 2014 with the objective of establishing a common
methodology to define electronic sensor performance. Units, test conditions and nomenclature were
defined, but left flexibility sufficient to allow for revision as new sensor technologies were introduced.
In spite of its noble goals, this document has not proven to bring the world of sensors into an industry-
wide state of standardization. And that may not be possible, at least for the foreseeable future.
As noted in earlier chapters, there are many types of sensors, each of which may utilize one or more
basic technologies to transform a physical property into analog or digital data. The degree of sensitivity
and accuracy vary widely depending on the technology as well as the intended application. The nature
of sensor applications that range from consumer to aerospace make it difficult to apply a common
7 -1
standard of performance. Finally, the network of large global sources and a highly fragmented market
makes agreement on universal sensor parameters a significant challenge. The result has been the
reality that there are no industry-wide standards that define sensor performance in effect today.
This is not to say that existing standards do not impact sensing devices.
Related Industry Standards

All software within a vehicle is regulated by the ISO 26262 standard which is a part of ISO 061508, which
defines functional safety of electrical/electronic /programmable electronic safety-related systems. This
standard will increase in importance as it applies to all safety-critical features that take control of
steering, speed and braking functions.
Healthcare devices require regulation by the FDA to insure they are electrically, chemically, biologically,
and physically safe for the end user. Implantable devices carry the highest level of scrutiny while a
digital thermometer poses limited harm. Emerging medical wearable devices are being outfitted with
low-power wireless radios that are addressed by the IEEE 802.15.4 standard.
ASTM is an international standards organization that develops and publishes voluntary technical
standards for a wide range of materials, products, systems, and services. A number of their standards
including E 1594-99, and E 344-01a are related to temperature terminology and calibration of
temperature sensors.
Rather than trying to standardize the performance parameters of the sensor itself, the industry has been
focused more on creating standards that define protocols and platforms which allow sensors to
communicate among themselves and to the next level of computation and communication. The ability
of many different types of sensors and actuators to be able to talk a common language would be
particularly important in IoT and IIot applications.
IEEE 1451.X is a series of standards that allows a system to identify, characterize, interface with and use
the signal generated by an analog sensor sent to an actuator. The -0 through 7 iterations address a
variety of application scenarios, while the -99 version is designed to harmonize devices in IoT
applications.
The IEEE 1451 family of standards includes:
• 1451.0–2007 - Common Functions, Communication Protocols, and Transducer

• 1451.1–1999– Network Capable Application Processor Information Model
• 1451.2-1997 – Transducer to Microprocessor Communication
• 1451.3-2003 – Digital Communication for Distributed Multidrop Systems
• 1451.4-2004 – Mixed-Mode Communication Protocols & TEDS Formats
• 1451.5-2007 – Wireless Communication Protocols & Transducer
• 1451.7-2010 – Transducers to Radio Frequency Identification (RFID) Systems
7 -2
Individual sensor types may be defined as compliant to a specific transmission protocol. The SAE J2716
SENT protocol for instance is a point-to-point communication system that can be used to transmit high
resolution data between a sensor and a controller.
Consortiums of involved companies are also playing a role in creating communication standards for
sensors and actuators. The Open Geospatial Consortium (OGC) is a group of over 500 companies,
government agencies, and universities with the objective of creating a series of open standards that
define interoperable solutions to complex data communication problems. One set of OGC standards,
defined as the “Sensor Web Enablement” standard framework, defines an infrastructure that allows
sharing of sensor resources, while minimizing complexity.
Using this protocol, web

connected sensors are able to
identify all devices in the
network and cooperate in
sharing data using
standardized interfaces. A
second OGC specification,
“Sensor Things API” is also
focused on establishing an
open channel for devices,
data and applications to
communicate over the web.
Efforts to promote sensor

standards for specific
industries include IO-Link
which is a global standard
that improves communication
among sensors and actuators
in industrial control
applications. Created by a
consortium of industrial
automation suppliers, it is
based on a point-to-point
connection between a sensor,
actuator or I/O hub and an
interface module.
7 -3
The resulting data can be used to increase productivity through sensor validation, improved diagnostic
capabilities, and overall reduced machine costs.
There are now over six million IO-Link nodes in service.
The MiPI (Mobile Industry Processor Interface) alliance is a standards organization that develops
interface specifications for the mobile and mobile-influenced industries. Similar to other application
segments, there have been no consistent methods for interfacing to sensors available to system
designers which makes sensor integration difficult and time consuming. As sensors have proliferated in
a host of new mobile devices, demand for an improved interface standard increased.
The MIPI I3C specification was released in 2016 and was intended to correct some of the technical
limitations of the defacto I²C communication standard. MIPI I3C defines a standardized sensor interface
used in such diverse applications as smart phones, wearable electronics, vehicles, and tablets.
The I3C sensor interface standard was created with three objectives.
• Standardize sensor communication

• Reduce the number of pins required by the communication link
• Support low-power, high-speed features provided by the I²C standard allowing backward
compatibility.
7 -4
Designing mobile products that conform to the I3C standard, system engineers can easily connect more
sensors, while reducing power consumption, component and implementation costs.
Even the United States military establishment has

recognized the dearth of sensor standards. Much of our
advanced military equipment depends on an array of high
reliability sensors that collect critical data under very harsh
conditions. Military subcontractors are normally required to
use only components that have been fully qualified to a
military standard making them more costly than commercial
equivalents but guaranteeing a higher level of performance.
Budgetary cutbacks and soaring costs of military hardware have stimulated interest in using commercial
grade components that are capable of satisfying performance requirements in mil/aero applications.
The Sensor Open Systems Architecture (SOSA) consortium was established with the objective of
reducing development time, increasing use of common components, facilitating interoperability and
ultimately reducing cost of new military systems that use sensors.
The SOSA consortium is creating open system reference architectures applicable to military and
commercial sensor systems, with a balance between performance and cost. The resulting modular
designs will speed implementation and reduce cost. SOSA working groups are currently in the process
of developing these open standards.
The issue of interoperability of IoT devices has been taken up by the National Institute of Standards
which has recognized the merger of the digital and physical worlds. NIST established the Cyber-Physical
Systems Public Working Group tasked with insuring data interoperability. Establishment of standards
for reference architecture, security, synchronization, and the ability to seamlessly share data will
remove barriers to the full realization of what the IoT offers.
Development / Prototype Kits
Lacking broad sensor standards, several industry leaders are offering

supplier specific design tools that can reduce design time for
implementing sensors into IoT products as well as assist in the design
of the sensor itself.
In an effort to overcome some of the challenges associated with the

integration of sensors in IoT applications, Bosch introduced the XKD
cross-domain development kit. Designed for system developers, this
wireless device contains a variety of common sensors along with a
simplified programming language that allows rapid prototyping of
new sensor based products.
The XKD module includes a Bosch accelerometer, gyroscope, magnetometer, inertial measurement unit,
humidity/pressure/temperature, acoustic noise, and digital light sensors. Also included is a 32-bit
7 -5
microprocessor with 1MB flash, and 128 kB RAM memory, Bluetooth 4.0 and Wi-Fi communication with
integrated antennas as well as rechargeable Li-Ion battery. The Bosch XKD kit incorporates many of the
design advantages of a traditional industry standard, but is specific to Bosch products, making it a
valuable marketing tool.
STMicroelectronics offers their

SensorTile modular designers kit that
supplies all the tools an engineer
requires to evaluate the performance
of a sensor circuit.
STM also offers development expansion boards that

enable testing of wireless connectivity.
Development / evaluation / prototype PCBs are typically

available for purchase from distributors and allow designers
to simply plug in the sensing function for a new product.
7 -6
Incredible demand for IoT devices that will

depend on input generated by MEMS
sensors is putting pressure on designers of
MEMS sensors to automate and accelerate
the design process. MEMS+ from Coventor
Inc. is a software platform specifically for
engineers who design and integrate MEMS
devices such as accelerometers, gyroscopes,
and microphones.
Emerging IoT applications are expected to require extensive customization of MEMS sensors making
device design accelerators highly attractive.
The unique character of electronic sensors will likely continue to make the establishment of widely
accepted standards challenging.
7 -7
Chapter 8
Chapter 8
Connector / Sensor Manufacturer Synergy
Introduction
Like any manufacturer in today’s globally competitive world,

connector manufacturers are driven to grow revenue. This has
traditionally been achieved by developing new and better
connectors while reducing costs. Connector companies would
introduce new product families based on the results of internal research and/or commitments from
major customers. Once tooled, a “state of the art” connector family could command premium prices
until a competitive interface appeared driving the market price down and starting the cycle over again.
This structure served the connector industry very well for many years. Industry leaders including
Amphenol, FCI Electronics (now part of Amphenol), Molex and AMP, now TE Connectivity, were often
able to charge customers much of the costs for tooling new connectors which after a period of time
became standard catalog items. Over time, the range of available connector types grew into the
thousands.
The advent of the internet and subsequent globalization proved to be disrupters to this business model.
Low cost of labor regions of the world recognized that they could manufacture commodity connectors
much less expensively, and at the same time, consumer demand driven by a growing middle class in
these regions provided a huge local market for electronic products. The globalization of the connector
industry greatly expanded the available market, but also spawned hundreds of competitors which
eroded margin. Reluctantly at first, American connector manufacturers began to move the manufacture
of commodity connectors and cable assemblies to off-shore locations that ranged from Mexico to China.
Very large manufacturers drew workers from the rice fields to urban factories where they could learn a
trade and earn wages far beyond their expectations. This new class of consumers increased demand for
all types of products further feeding the demand for more workers, eventually making the Asian market
the largest and fastest growing in the world.
As the migration of manufacturing and local product demand grew, it made sense to provide increased
local support in the form of sales and marketing personnel. Eventually Asian based manufacturers grew
to the point that they assumed design responsibility, which necessitated moving cadres of domestic
connector design engineers to Asian locations. In some cases, U.S. based companies would simply
provide a specification for a new product, leaving the actual design work to Asian engineers. Many
connector manufacturing plants located in the United States were closed.
Along with connectors, the ability to design and manufacture complex state of the art interfaces based
on new technology also migrated overseas. Low-cost commodity connectors were the first to be
transferred to off-shore locations in order to remain competitively priced. High-speed / performance
connectors initially remained in the U.S., but as off shore technical competence increased, that too
changed. Today, the most advanced backplane and I/O connectors may be designed and prototyped in
the U.S., but then quickly transferred to Asia for volume manufacturing.
8 -1
All of these changes have increased pressure on leading connector manufactures to find new avenues of
growth. Electronic sensors may be exactly what the industry is looking for.
Actually, a number of connector manufacturers had already been participating in the sensor market.
Over the years, a series of minor acquisitions had allowed several connector manufactures to enter the
sensor market. These initial forays into the world of sensors may have been driven by a major OEM
customer that required a connector with an integrated sensor, or simply was part of an acquisition that
provided access to a different type of connector expertise. Sensors might have had little visibility from a
company that is recognized as a leader in the connector business. These sensors focused on niche
applications, and were often not actively promoted as a significant product line.
A number of potentially disruptive technologies are now converging that is propelling huge growth of
electronic sensors making them an attractive market in which to make a major commitment. These
factors include:
• The Internet of Things (IoT). Sensors are the eyes and ears of the IoT. Literally billions of
sensors will be integrated into nearly everything we touch and do.
• Industrial Internet of Things (IIoT). Industry 4.0 is poised to transform the entire manufacturing
process from raw material to finished product. Factory automation will require thousands of
sensors that report on every step of the process. These sensors will be linked via a high-speed
often wireless networks to processors that utilize artificial intelligence that will improve quality,
reduce scrap, and speed time to market.
• Growth of cloud computing as well as storage in the cloud will enable sensor networks to upload
data and make it available anywhere in the world.
• Autonomous transportation is the wave of the future. Large multinational companies are
investing billions of dollars to develop the hardware and software necessary to insure safe
transportation that eliminates human error. The vast array of sensors already integrated into
vehicles today will be augmented with many more ruggedized sensors that will deliver high-
speed/resolution data required to safely navigate a vehicle.
• Already, artificial intelligence is being integrated into networks and even down to individual
sensor modules, enabling them to not only collect data but make informed choices locally.
• Ethernet has published a performance roadmap that defines 400 Gb/s channels now, and an
800 Gb/s migration path. The ability to continually upgrade Ethernet is essential in order to
keep communication systems from becoming a data bottleneck.
• Gen5 cellular systems will open up entirely new channels of high-speed connectivity with
reduced latency and much increased bandwidth, further enhancing mobile communications
between people and machines.
8 -2
• Robotics are evolving from a few heavy industrial applications to mass markets for low cost
devices that can work directly with people in an assembly atmosphere, perform tasks of a
personal assistant, provide medical delivery, and even act as a personal companion. An array of
sensors provides the robot with the input needed to take on a variety of tasks which are now
much easier and quicker to program. Robots with added artificial intelligence will sense
surroundings and voice commands to accomplish tasks without programming.
• Finally, advances in battery chemistry as well as advanced extremely low power semiconductor
technology are opening entirely new mobile applications. The typical smartphone today may
sport up to 10 sensors, but plug-in accessories studded with advanced sensors will be capable of
analyzing blood for diagnosis of disease, measuring water and air pollution, as well as convert
gestures into action. Increased energy density will enable smaller batteries with extended
battery life. Together with systems that operate on a few femtowatts of power, advanced
energy storage devices are key requirements for next generation mobile devices.
Each of these emerging technologies will require the gathering and processing of information about the
environment in order to function, placing sensors of all types at the front end of the communication
chain. High volume components such as sensors that are often attached to a wire or printed circuit
board are a logical extension of connectors that are also high volume components often attached to a
wire or PCB.
The addition of sensors to a connector manufacturer’s product portfolio also supports original
equipment manufacturers (OEMs) preference for an end-to-end solution to the packaging of a new
product. Rather than work with different sources for every
component they require, OEMs like to work with suppliers that offer
value-added assemblies. In the case of connector manufacturers, a
sensor molded into a custom assembly with an integrated connector
or with an attached cable allows the system designer to move on to
other issues. The OEM buyer can minimize the task of dealing with
multiple sources; while
manufacturing
management can simply
plug in an assembly
they would otherwise
be responsible for building. Vendor reduction programs
have been going on for years among large OEMs in an
attempt to work more closely with a reduced supplier base.
The ability to sell multiple related components enhances a
vendor’s value to the OEM.
Adding sensors to an extensive line of connectors enables the connector vendor to leverage their
existing internal capabilities. For example, most of the larger connector vendors now have internal
cable assembly resources. In some cases they draw the wire, extrude different jacket materials, bundle
the wires, add a solid or braid shield, and add the outer jacket. They may offer discrete, twinaxial, and
coaxial cable construction.
8 -3
Attaching a connector at one or both ends of a wire is a core competency. Connector companies have
vast experience in making recommendations of the most appropriate separable interfaces across the
entire range of environments. In addition to electrical performance, they can analyze the application
and make appropriate recommendations on the type of contact plating, environmental sealing, housing
material, locking mechanism, termination method, reliability as well as resistance to shock and
vibration. All of this is valuable input that can result in a better assembly design.
Many sensors are attached to flat flexible cable

which allows a sensor assembly to be folded into
a cramped space or allow movement between
two parts of the equipment. Many of the larger
connector manufactures have had in-house
custom flat etched circuits design and
manufacturing capability for years. Adding a
sensor to a flex circuit at one end and a
connector at the other is an ideal assembly for a
connector manufacturer.
The connector manufacturer is able to sell a higher value product, potentially with greater margin, while
shutting out competitors offering only individual components. The ability to offer value-added sensor
assemblies also may give the connector vendor access to system designers much earlier in the design
cycle. The result may be insight on additional connector and sensor sales opportunities well before
competitors arrive. Pairing connectors with electronic sensors offers the possibility of increasing sales of
both component types. Adding sensors to the product line can dramatically increase the total available
market (TAM), a key objective of a connector manufacturer.
As noted earlier, several connector suppliers have included a select line of sensing devices in their
portfolio for years, often to support a major customer or targeted market segment. In order to increase
their commitment to sensors, connector vendors have largely chosen to pursue two strategies.
Rather than try to take on the entire universe of sensors, some connector manufacturers have identified
select niches that are a particularly good fit with their existing resources and corporate direction. They
may choose to introduce a single type of sensor that is often purchased along with a connector by a
large OEM customer. The sensor may be supplied by acquiring a small independent manufacturer, or
simply purchased and sold as a private labeled product. In other cases, a connector manufacturer may
opt to participate by applying a specific expertise such as custom packaging of a sensor to produce
unique combinations of sensors or those that are integrated into a housing that may include a
connector.
As an alternative approach, a select number of leading connector manufacturers have increased their
sensor capabilities through an aggressive process of acquisition rather than developing sensor resources
internally. The fact that the sensor industry is highly fractured with literally thousands of independent
manufacturers provides plenty of opportunities to acquire the exact mix of desired resources. Direct
purchase also speeds the ability to enter the sensor market than if grown internally. Proven
technologies, established manufacturing processes, and access to an existing saleable product line takes
8 -4
out some of the risk involved in expanding into new markets. Having a base of current customers is
helpful also. The acquired sensor vendor gains from having access to technical and financial resources
not possible as an independent. Exposure to a global customer base serviced by an established sales
and technical support team can quickly multiply the number of available business opportunities. A
positive global reputation also adds credibility that a small independent supplier could not even
imagine.
The process of working with customers in the specification and sale of connectors and sensors is often
quite different. It may involve different people within component engineering with entirely different
technical requirements and objectives. Sensors and connectors may also be specified at different stages
of the new product design process, but both are critical to the successful launch of a new product.
Discussions with several large connector companies confirmed that their connector sales force is
provided basic training that enables them to identify sensor opportunities. These field sales people pass
the opportunity to a team of sensor specialists that have deep understanding of sensor technology as
well as application experience. They take over responsibility for the pursuit, engineering support and
sale of the sensor. Account managers are able to coordinate the overall sales effort.
The following pages review how three large connector manufacturers are responding to the business
potential offered by the addition of electronic sensors.
Additional connector manufacturers that have chosen to participate in the market for electronic sensors
are also reviewed.
8 -5
Amphenol Advanced Sensors

Amphenol, the world’s second largest
connector manufacturer has been actively
adding to their roster of electronic sensor
manufacturers. Their product line
expansion into the world of sensors began
in 2013 with the acquisition of the
Advanced Sensors group from General
Electric Measurement and Control
Solutions. Many of the sensing devices
acquired from this purchase target transportation, medical, pharmaceutical, and industrial rather than
consumer applications which complements Amphenol’s reputation for high-reliability, ruggedized
connectors and cable assemblies.
Organized as a group of separate business units under the Amphenol Advanced Sensors banner, each
company brings a unique sensor capability that can be applied to a diverse range of customer
requirements with specific focus on automotive, medical and industrial applications. Amphenol
markets their sensor products under the following brands.
• KAYE – Manufacturer of validation and environmental monitoring sensors
• Protimeter – Specializes in moisture meters
• Thermometrics – Temperature sensors
• Nova Sensor – MEMS pressure sensors
• Telaire – CO2 and humidity and dust sensors
KAYE manufactures precision temperature probes, sensor

validation systems and software used to insure
measurement equipment accuracy. Their validation
systems combines accurate sensor measurements for
calibration and traceability to national standards, while
generating compliant reports and managing the validated
equipment.
They also make high accuracy, traceable temperature

probes ranging from -196°C to 420°C used for calibrating
sensors.
8 -6
Protimeter moisture meters include a wide range of

professional hand-held instruments that measure the
degree of moisture on and below the surface of many
materials as well as the relative humidity and
temperature of the ambient air.
Thermometrics manufactures a broad line of temperature

sensors including Inrush Current Limiting Thermistors,
infrared sensors, positive and negative temperature
coefficient thermistors, turbidity sensors as well as
temperature standards and custom sensor assemblies.
These sensors are used in a variety of markets including

transportation, industrial automation, medical, HVAC and white
goods.
Thermometrics markets discrete sensors as

well as leaded cable assemblies such as
these oil temperature sensors.
8 -7
NovaSensor specializes in the manufacture of MEMS

pressure sensors and transmitters
These sensors are used in medical, biomedical, industrial control, and

transportation equipment.
NovaSensor also markets pressure sensing die that can be

provided in both wafer and chip form.
Telaire specializes in the manufacture of humidity, dust, and

CO2 sensors used in HVAC, refrigeration, appliances, process
control instrumentation, medical instruments, weather
stations, and automobile cabin climate control applications.
ChipCap 2-SIP humidity sensor assemblies integrate a capacitor,

CMOS IC with an EEPROM in a single individually calibrated and
tested package.
8 -8
Amphenol Advanced Sensors continued to expand their portfolio of sensors with additional acquisitions
in 2017. In August, Meggitt, a British engineering firm sold three sensor businesses to Amphenol.
Acquisition of the three companies added approximately $75 million in annual sales to Amphenol
Advanced Sensors.
Wilcoxon Sensing Technologies, located in Germantown,

Maryland specializes in high-performance vibration sensing
and monitoring solution that are used to monitor the condition
of rotating machinery including motors, pumps, fans,
compressors, gearboxes, and cooling towers. Many Wilcoxon
products are based on piezoelectric accelerometer technology.
Vibration monitoring equipment enables predictive

maintenance of critical equipment. Detection and repair of
mechanical equipment before failure occurs can more than
justify the cost of precision monitoring equipment.
Many of their sensors are designed for high temperature harsh environments typically encountered in
industrial applications.
Wilcoxon also manufacturers a broad selection of ruggedized

sensor cable assemblies.
8 -9
Piezo Technologies specializes in production

of advanced piezoelectric ceramic materials
typically used in acoustic and ultrasonic
sensors.
Based in Colorado, they manufacture an extensive line

of piezoelectric materials as well as custom high-
performance ultrasonic transducers for medical and
industrial applications.
These unique materials are used in a wide range of

devices including accelerometers, level and flow
sensors, air-in-line sensors, engine knock sensors as
well as medical therapeutic equipment.
Piezo Technology offers their customers engineering

support in the development of custom piezoelectric
devices.
PIHER Sensors & Controls SA is based in Spain, and

offers an extensive line of magnetic rotary and
position sensors. Their product list includes Hall
Effect contactless sensors, seat belt sensors, HVAC
sensors, multi-turn sensors, and rotary concentric
non-contact sensors. They also offer engineering
expertise to design custom sensors.
8 -10
PIHER supports applications in automotive, consumer appliance,

industrial automation, instrumentation, medical, and agriculture
equipment.
Also in 2017, Amphenol acquired i2s from Intelligente

Sensorsystems Dresden GmbH. i2s offers sensors for
measuring pressure, mass, air flow, temperature,
force, and humidity. They are also able to create
custom combinations of multiple sensors in a single
package.
A Climate Control Pressure Transmitter (CCT) was specially

designed for measuring the pressure of vehicle coolants. The
hermetically sealed, robust aluminum case makes this sensor
ideal for vehicle climate control systems
i2s also makes one of the smallest yet robust oil pressure sensors designed
for consumer and commercial vehicles. Sensors can be designed to be
submersed in oil up to 150°C.
8 -11
Amphenol Advanced Sensors sees their core strength in their portfolio of selected sensor technologies
as well as the technical resources available within the Amphenol Corporation. The management
structure of Amphenol Advanced Sensors allows greater flexibility and rapid response capability to
emerging business opportunities.
Similar to their high-performance connector products, Amphenol sensors may use proprietary materials,
advanced manufacturing processes and unique features such as self-calibration to achieve a competitive
advantage. Many of the business units within Amphenol Advanced Sensors group are equipped to
address custom variations of standard products, further enhancing value to both the customer and
Amphenol.
Sensors along with integrated connectors and cable assemblies present a classic value-added
proposition for their customers. The strategic acquisition of sensor suppliers is intended to avoid
markets that will utilize commodity sensors, while concentrating on applications where accuracy,
dependability, and durability are more important than unit price.
8 -12
Molex Sensor Solutions

Molex is in a very early stage of participating in the market for electronic sensors. To date they have
made a limited number of strategic acquisitions that complement their extensive product lines of
connectors and cable assemblies.
Sensorcon, a manufacturer of portable carbon monoxide

and hydrogen sulfide gas detectors was acquired by
Molex in 2014.
These sensors are designed for rough field service and

are water and shock proof.
Sensorcon devices are used in HVAC, automotive,

aviation, fire, rescue, transportation, water treatment,
and home inspection applications.
In 2015 Molex acquired Soligie Inc. a printed and flexible electronic circuit business to complement their
existing line of membrane switches, polymer thick film circuits, copper flex circuits, and printed circuit
board assemblies.
Soligie Printed Electronic Sensor Systems
specializes in printed and flexible sensor
assemblies that can incorporate a wide
variety of discrete components. The result is
highly customized sensor assemblies that are
manufactured in a cost-effective roll-to-roll
assembly process.
Soligie circuits can include LCD/LED displays,

microcontrollers, RFID, wireless communication chips,
batteries, antennas, energy harvesting devices as well
as a wide variety of sensor types. The result is thin,
lightweight, and flexible sensors.
Applications for these flexible sensors exist in

aerospace, environmental monitoring, security
medical, industrial, and wearable consumer products.
8 -13
Another aspect of the Molex stable of sensing technologies is

their ability to design and manufacture capacitive fluid level
sensors. Unlike mechanical floats and switches that require
direct contact with the liquid, capacitive fluid level sensors
are able to measure the levels of fluid or granular material
from outside of any non-metallic container with no moving
parts.
Combined with configurable software, these sensors provide

simple installation, higher accuracy, and long service life.
They provide the ability to measure caustic or explosive
liquids that may be difficult or impossible to measure with
traditional mechanisms.
Sensors can either measure precise quantities of a liquid or simply detect and alert when a liquid has
reached a certain point. Capacitive sensors also allow much more design flexibility, while customized
software can adjust for unusual application requirements.
Sensing assembles like this are a perfect

example of leveraging Molex connector, cable
assembly, PCB assembly, and sensor
capabilities.
Applications for these capacitive sensors include industrial process control, consumer appliances,
medical devices, and automotive fluid sensing.
In addition to its extensive roster of flexible films used as a

substrate for etched or printed circuitry, Molex also
manufactures custom capacitive touch sensors using
PEDOT based material.
Featuring excellent electromechanical and thermal

properties, Molex PEDOT is a transparent conductive
polymer coating that blends conductivity, optical clarity
and unlimited finger-control cycles in highly demanding
switch applications. The clarity of this touch sensitive pad
allows easy backlighting, while the flexibility enables
attachment to other than flat surfaces.
8 -14
This technology can be utilized in both touch and proximity sensing applications.
Sensors are attached to the surface using pressure sensitive adhesive.
Typical applications for these touch switch solutions include aviation systems, ATM terminals,
appliances, fitness equipment, hot tubs, barcode scanners, telecommunications two-way radios, mobile
phones, routers, servers, and industrial automation equipment. They also can be used in a variety of
medical applications including defibrillators, EKG leads, glucose meters, portable oxygen units, infusion
pumps, and patient monitoring devices.
The immense growth potential of electronics in automotive applications makes this segment highly
attractive to all component manufacturers. Molex is a major supplier of sealed and unsealed
automotive connectors, and cable assemblies that enable critical functions in power train, driver assist,
body electronics, passenger comfort, infotainment, and emerging connected car applications.
Molex is participating in the automotive sensor segment by offering the ability to package a sensor and
connector into a single pluggable assembly. Molex automotive sensor assemblies may include:
▪ Air bag sensors ▪ Radar sensors

▪ Driver assistance systems / convenience ▪ Rollover sensors
▪ Knock sensors ▪ Safety
▪ Mass airflow sensor ▪ Temperature sensors
▪ Parking sensors ▪ Tire Pressure Monitoring Systems
▪ Power Train (TPMS)
▪ Pressure sensors
Multiple sensing devices as well as wireless communication functions can be integrated into the
assembly.
Molex crash sensor assemblies are custom designed for

each application and incorporate their extensive
connector design expertise for components in harsh
automotive applications.
8 -15
An automotive air-flow sensor package leverages

Molex experience in fabricating precision lead
frames along with insert molded plastic
assemblies.
In addition to the option of purchasing external sensor resources,

Molex established a strategic investment platform seeking
relationships with companies and institutions that share promising
business strategies and technologies. One of these ventures
involves Oak Ridge National Laboratory in an effort to develop low-
cost wireless sensors. Prototypes have been produced and are
undergoing evaluation.
As part of the Transcend Network Connected Lighting system, Molex also offers wireless room
occupancy and ambient light sensors.
8 -16
TE Connectivity Sensing Solutions

TE Connectivity is recognized as the world’s largest manufacturer of electronic connectors with over $14
billion in annual sales. Their extensive family of interconnect products support applications that range
from aerospace to consumer. A limited line of pressure and position sensors had been part of the
original AMP Inc. product line in support of the automotive and aerospace market but corporate
direction toward expansion into higher growth rate products along with the name change to TE
Connectivity slowly evolved starting in the early 2000s.
The $1.7 billion acquisition of Measurement Specialties in 2014 propelled TE from an incidental source
to becoming a major player in the rapidly growing electronic sensor industry. TE product offerings
immediately expanded to include temperature, humidity, vibration, and force sensors. Established
sensor sales in entirely new markets such as industrial, transportation, health, appliance, and consumer
dramatically increased the total available market to TE.
Later that year, TE announced the addition of American Sensor Technologies Inc. to their sensor
portfolio. American Sensor products focused on applications in harsh and extreme environments in
industrial, marine, energy generation, defense, and aerospace markets. These products complemented
TE’s refocus and concentration on ruggedized interconnects designed for harsh environments.
In order to further support their commitment to expanding their sensor products, TE opened a new
facility in Andover, Minnesota dedicated to design and manufacture of highly engineered temperature
sensors.
In May of 2016, TE announced the acquisition of JAQUET Technology Group, a Swiss based leader in the
design and manufacture of speed sensors used in auto, rail, aerospace, and power markets. This
addition further cemented TE’s capabilities as a global source of highly engineered interconnect and
sensing devices.
The result has enabled TE to actively promote an extensive portfolio of sensors to the total range of
industry segments including automotive, industrial, medical, appliance, aerospace, defense, consumer
automotive, and industrial and commercial transportation.
The many types of sensors offered by TE include:
Air flow Angular rate gyros, accelerometers and Inertial

Flow switches Torque
Humidity Speed
Temperature Traffic
Fluid Property Ultrasonic
Photo optic Vibration
Force Water Level
Piezo film
Position
Pressure
8 -17
TE also offers custom designed multi-sensor modules, engineering development boards as well as a line
of temperature and pressure sensor data scanners.
The depth of the TE sensing product line is impressive.
Bi-directional and unidirectional mass air flow sensors are

thermodynamic sensing elements for the measurement of mass air
flow. They are used in engine air and industrial gas flow
applications.
Liquid flow sensors utilize reed switches for reliability.

They are compatible with a wide range of liquids found
in automotive, medical, and industrial applications.
Humidity sensors using TE capacitive technology

measure dew point by combining temperature and
humidity measurements. Individual humidity sensing
components as well as assemblies are available. These
sensors are commonly used in refrigeration applications.
TE offers a variety of temperature sensors using multiple

technologies including thermistors, thermopile, resistive
temperature detection, thermocouple, and infrared.
Sensors that generate analog, digital or custom output are

available.
8 -18
Temperature sensors are packaged as PCB assemblies,

surface mounted chips, or leaded assemblies.
Temperature sensors are used in nearly every market

segment including consumer, industrial control, aviation,
white goods, medical, and military applications.
Fluid property sensors combined with custom

algorithms are able to measure viscosity, density and
dielectric constant in engine, hydraulic and
transmission oils and fuels using near infra-red (NIR)
or ultrasonic technologies. These sensors can also
be equipped with reed switches for level sensing. A
new water-in-oil sensor has recently been added.
TE photo-optic sensors are designed for applications that

range from patient monitoring, to wearables and home
healthcare applications. Photo optic sensors are
available both as individual components and complete
sensor packages. TE SpO2 sensors offer design flexibility
to accommodate multiple wavelength options.
TE force sensors enable OEMs to measure force using MEMS-

based technology load cells. Proprietary piezoresistive silicon
strain gage technology can also be configured into a reliable,
low-cost package to measure force. These sensors are used in
consumer, medical, industrial, robotics, compression sensing,
variable tension control, and seat occupancy detection
applications.
8 -19
Piezo film sensors provide durable vibration,

accelerometer, or dynamic switch elements used in a
wide range of markets and applications. Piezo sensors
are available in various forms including film, cable,
and miniature elements in standard and customized
packages. They are lightweight and available in
various sizes and thicknesses.
TE position sensors include, angular, linear displacement, tilt, rotary, magnetic, and liquid level types.
Within each category, position sensors are available in

multiple off-the-shelf and custom configurations,
These sensors are designed for long reliable service live in

harsh environmental conditions.
Sensors can be supplied with wire leads or terminated

with an integrated connector.
Standard and custom pressure sensors from TE range

from the individual sensing element to those packaged
for harsh environments. These sensors utilize
piezoresistive, micro-electromechanical systems (MEMS),
and silicon strain gauge technology to accurately
measure a wide variety of liquids and gasses. Digital or
analog outputs are available.
8 -20
An extensive line of reliable, cost-effective PCB

mounted, media isolated pressure transducers find
applications in medical, test and measurement,
automotive HVACR, off-road, heavy equipment,
hazardous location, and general industrial
applications.
Angular rate gyros, accelerometers, and inertial

sensors are designed for applications including
automotive crash testing, robotics, biomechanics, as
well as test and measurement. They are packaged in
standard and custom anodized aluminum and
stainless steel housings for durability.
Torque sensors measure reaction and rotating torque

and include protective mechanical stops.
Combination sensors measure both reaction torques
and forces. These sensors can also detect angle
position and provide velocity measurements. Custom
configurations are also available.
8 -21
The JAQUET brand of speed sensors from TE focuses

on applications in demanding and harsh conditions.
These mostly customer specific sensors are based on
active eddy current, passive eddy current, hall-effect
or variable reluctance principles. Sensors are rated
for operating temperatures from -40°C to 300°C peak,
with rotational speeds from zero to 400,000 rpm.
Highly accurate traffic sensors are designed for

vehicle speed and classification applications. They
are robust, low cost, easy to install, and offer
excellent signal-to-noise ratio. Axle sensors, using
piezoelectric cable, are suited for dynamic
applications such as weigh-in-motion, speed, counts
and red light cameras. TE also offers fiber optic axle
sensors that are suited for toll applications. These
sensors use fiber optic light-based technology instead
of contact for improved accuracy and reliability.
TE offers a wide range of sensors using ultrasonic

technology. They are used to measure liquid level
despite variations in transparency, viscosity, color, or
dielectric. They provide high accuracy, short range
continuous measurement through air for process
control with no moving parts, adjustments, or
maintenance. They are compatible with a range of
liquids and gases in direct contact with the media
Applications include air bubble detection for medical pumps, point and continuous level sensors for the
semiconductor and high purity markets, and point level sensors for a variety of process control
applications.
8 -22
Vibration can be measured using DC-response

(static) or AC-response (dynamic) accelerometers.
TE sensors utilize proprietary MEMS, bonded gage

and piezoelectric ceramic/film technologies. Charge-
mode piezoelectric accelerometers measure shock
and vibration in high temperature environments.
Industrial vibration sensors are available in many

configurations from above ground to submersible.
From 4-20 mA signal outputs with connector or
integral cable are optional.
TE analog and digital water level sensors are designed

for applications in monitoring water usage and
quality. They are capable of operating in water
pressures that range from 1 to over 3000 PSI.
In addition to these “standard” sensor types, TE also

specializes in the design of highly application-specific
sensors such as this pulse oximetry cable assembly.
Unique sensor assemblies required in medical,

automotive, and avionic applications may incorporate
multiple sensors, integrated into custom metal or
plastic enclosures.
8 -23
This custom automotive dual clutch

transmission sensor module
measures drive mode position and
gear speed using active PLCD or hall
technology.
TE linear position sensors designed for use in

commercial aircraft provide feedback to the cockpit
to ensure thrust reversers have properly deployed.
TE also supports design engineers with sensor

development modules and kits that allow
quick performance analysis and
implementation of sensors into a new
product.
8 -24
Additional Connector and Sensor Manufacturers

In addition to these three major connector manufacturers, many more, primarily connector suppliers
have maintained or expanded their sensor product lines.
AVX Corporation manufactures a broad range of passive

electronic components including connectors that support multiple
industries. They acquired AB Electronik, the Transportation,
Sensing and Control Division of TT Electronics in October of 2017
which added greatly to their existing line of leaded, disk and
surface mount thermistors. Many of these sensors are related to
automotive applications.
Sensing product lines acquired from TT Electronics and now sold

under the AB brand includes:
▪ Temperature sensors
▪ Hall Effect & conductive plastic position sensors
▪ Hall Effect & inductive rotary speed sensors
▪ Inductive & capacitive proximity sensors
▪
Foxconn, (now FIT), lists sensors and actuators as a

segment in their mix of hardware. Foxconn acquired
access to image sensing technology with its
acquisition of Sharp. Foxconn also took an equity
position in Dyna Image, which markets optical,
inertial, and environmental sensors in China. They
also invested in Sotera Wireless, a manufacturer of
medical monitoring devices. Foxconn is providing the
sensors and batteries to Sotera.
Hirose is a source of many high-density connector systems but also lists a very limited (two items) line of
electro-static sensors that are used in copiers and printers as well as in the production of
semiconductors.
8 -25
In addition to its line of connectors, JAE manufacturers several types of sensors for use in energy
exploration, aviation, automotive, and industrial control applications.
JAE high performance magnetometers and quartz servo

accelerometers offer high accuracy downhole performance under
conditions of extreme vibration, temperature and shock.
A line of directional modules are used in directional and horizontal drilling applications.
Automotive resolvers are used in the drive chain to provide

accurate angle measurement with integrated angle error
compensation to control the rotation of the motor.
Methode Electronics entered the sensor industry with its acquisition of TouchSensor Technologies in
March of 2007. TouchSensor products utilize
patented semiconductor technology to produce field-
effect switches and touch panel user interfaces.
IntuiTek keypads feature zero force, low and high
resolution options, and are effective with thick
substrates and gloved hands. These sensors are used
in applications that includes consumer white goods,
automotive, and industrial control applications.
Methode also manufactures multiple sensors related

to automotive applications including transmission,
steering angle, clutch plate position and toque
sensors.
8 -26
A series of fluid level sensors, marketed under the

LevelGuard brand, use capacitive and field-effect
technology to support marine and recreational
vehicle applications as well as industrial pump and
residential sump pump controls.
OMRON, headquartered in Japan, is a highly diversified manufacturer of components, automated

equipment and systems including medical devices. Part of their component offering includes an
extensive line of cable-to-board, board-to-board and FFC/FPC connectors. The Industrial Automation
Division of OMRON offers a variety of sensors designed to complement their automated production
systems. The list of sensor types includes:
▪ Fiber Sensors
▪ Photoelectric sensors
▪ Displacement / measurement sensors
▪ Vision sensors use in machine vision applications
▪ Ultrasonic, capacitive and optical proximity sensors
▪ Liquid sensors
Omron laser proximity sensors are able to

provide fast, stable distance measurements
without loss of accuracy on absorbent or
reflective surfaces.
8 -27
Samtec, a major supplier of high-performance

connectors has chosen to participate in the
sensor market from a different perspective.
Rather than acquire sensor manufacturers
and add sensors to their list of products
Samtec is continuing to enhance their
microelectronics packaging capabilities which
can be applied to the manufacture of
electronic sensors.
Samtec got into the electronic packaging

business with the acquisition of Alpen IO and
Aspen Technologies in 2011, and expanded into 3-D packaging, sensor modules and wireless
connectivity with the purchase of Triton MicroTechnologies and nMode Solutions in 2016.
The Samtec Microelectronics facility, located in Colorado

Springs has become the technology focal point for
enabling their silicon-to-silicon interconnect concept.
This location specializes in chip-level packaging which
includes micro wirebonding, IC packaging, microfluidic
devices, MEMS assembly, stacked die, high-performance
redistribution layers using Glass Core technology as well
as signal integrity, modeling and simulation support.
In the sensor arena, Samtec is operating much like an Outsourced

Semiconductor Assembly and Test (OSAT) supplier. They either
purchase or receive bare wafers or individual sensing die from
their customers, and apply their expertise to package and test the
finished component. Samtec specializes in highly customized and
complex assemblies and packaging challenges that an average
OSAT cannot address. Samtec Microelectronics has packaged
biomedical sensors for over 20 years, including an implantable
blood pressure sensor, implantable audio sensor, miniaturized MRI
sensor and miniaturized ultrasound imager. The have also been
active in packaging microfluidic devices which allows Samtec to
leverage their precision assembly and packaging with their
extensive line of subminiature and micro interconnect systems.
8 -28
At the other end of the connector industry spectrum is Sensata

Technologies. Primarily a very large manufacturer of sensors,
aircraft grade circuit breakers, switches, commercial
multifunction joysticks, inverters and chargers, they also offer
an extensive line of semiconductor test and burn in connectors.
The list of Sensata sensors includes:
• Strain Gauges
• Position
• Rotary motion
• Pressure sensors and switches
• Temperature
• Speed
• Brake force
• Airflow
Sensata makes sensors that are used in nearly every industry segment,
but specialize in heavy duty, professional grade sensing devices used in
medical, industrial, and aerospace applications.
Vishay manufactures a very narrow selection of PCB edge and rack and panel connectors along with a
broad lines of ceramic thermistors, thin film-based resistive temperature detectors, as well as angular,
linear and non-contact position sensors.
8 -29
Yazaki is a major manufacturer of power and data connectors, cable assemblies, instrument clusters,
head-up displays and safety warning devices primarily focused on automotive applications. They also
have developed a number of related sensors including a
non-contact fuel level sensor, compass sensor as well as
a coreless hall-effect current sensor.
8 -30
Chapter 9
Chapter 9 Sensor and Application Trends

The world of sensors and their application is far from static.
Sensor technology continues to evolve in terms of accuracy,
durability as well as the fusion of multiple sensors, processing
power, and wireless communication in a shrinking package.
Sensors are being employed in new innovative applications
that are bringing the promise of the IoT, autonomous
transportation, Industry 4.0, personal fitness and 24/7 medical monitoring closer to reality.
The pace of these advances, enabled by improved battery chemistry, greater semiconductor chip
integration that conserves space as well as minimizes power requirements, advanced algorithms and
artificial intelligence is unprecedented. These rapidly evolving technologies are opening new avenues
for market growth that progressive companies want to tap into. The quest for future revenue growth
has lead companies across the entire spectrum of electronic component suppliers to move into new
segments by acquisition. Arrow Electronics, a global electronics distributor recently acquired San Jose
based eInfochips, a product engineering and semiconductor design services firm, which will expand
Arrow’s value-added resources.
The linkage between sensors and connectors enables the conversion and transfer of critical data from
the physical world to a form that can be understood and acted upon by computers. The anticipated
explosion of new applications for sensing devices is providing a powerful incentive for connector
manufactures to expand their portfolio of sensor related products. They see the advantages of end-to-
end solutions as an excellent opportunity to bring greater value added advantages to their customer
while increasing their total available market potential.
The following is a snapshot of some aspects of how sensor technology is being employed, how the
sensor manufacturing industry is evolving and what the near-future portends.
General Sensor Issues

Integration of multiple sensors along with additional filtering, amplification, computation and
communication functions into a single package continues to make advances. The most current devices
integrate temperature, humidity and pressure along with noise filters, power management,
microprocessor, and RF radio in a land grid array surface mounted package. Availability of these devices
shortens the design cycle and frees up valuable PCB space.
The trend toward “smart everything” is driving demand for ever smaller semiconductor chips that
incorporate more functions. Devices designed with nodes as small as 5nm offer excellent density, but
huge manufacturing challenges as well as cost. Anticipated applications in transportation including
vehicle connectivity, advanced infomatics, navigation, and collision avoidance will add many more
sensors and processors in challenging environments including under-hood extremes. Proximity of these
devices to sources of EMI and ESD will present even more challenges for critical systems that impact
human safety.
9 -1
With billions of sensors connected to networks expected within the next few years, the ability for them
to communicate will be essential. That level of connectivity would swamp existing mobile cellular
networks. Introduction of the 5G protocol is anticipated to be the solution as each 5G cell is expected to
be capable of supporting data transmission from 250,000 sensors without compromising the quality of
regular cellular communications. Sensor data communication directly to the cloud is becoming more
common. An alternative protocol would allow low-level communications to occur at more distributed
computation sites, closer to the application, reducing latency and freeing up core servers for more
complex tasks.
The New Car Assessment Program, (NCAP) is a U.S. government auto safety program charged with
evaluating new car design that impacts passenger safety. Car safety is measured by performance in
standardized crash tests. Advanced Driver Assistance Systems (ADAS) such as collision avoidance,
automated steering, and contextual awareness will require the use of advanced optical, ultrasonic,
radar, and lidar sensors. The current relatively high costs associated with lidar sensors is a particular
concern, but next generation lidars will reduce both size and cost enabling them to be implemented in
mass produced cars. The US Department of Transportation is expected to include ADAS in their STAR
rating system for new cars as early as 2019. It is unclear at this point how state of the art ADAS systems
will impact the performance rating as well as the overall cost of the vehicle. Many of the advanced
ADAS features to date have been limited to high-end tier one vehicles. In some cases, the reliability of
these electronic systems has been questioned. The question is how system reliability will be impacted
when ADAS features are integrated into high-volume production vehicles. The ADAS market was
estimated at $32 billion in 2017 and is expected to reach $60 billion in 2025.
Sensors employed in military applications are expected to grow logarithmically over the next five years.
Chemical property, proximity, and positioning sensors are expected to show the most growth over this
period. They will be used in such diverse applications as biological agent detection, target detection,
surveillance, and augmented vision systems. With massive amounts of input data streaming from
potentially thousands of sources, the challenge becomes making actionable sense of this data.
In response, the Department of Defense has created the Sensing Information Analysis Center which uses
massive storage and advanced pattern recognition to weed through reams of data to identify important
information. With a similar objective, the Defense Advanced Research Projects Agency (DARPA)
initiated the Mathematics of Sensing, Exploration, and Execution project which issues grants for
development of mathematical models that can streamline the analysis of sensor generated data. In the
consumer world it is estimated that there are over six billion connected devices that are generating tens
of exabytes of data every month. Given the anticipated growth rates of the IoT, this number will
continue to grow making it imperative that new machine-learning algorithms and software is developed
to bring value to all this input. It is hard to imagine the potential value as well as threats that can be
gleaned from streams of data generated by such diverse sources as, the Amazon Echo, a home
thermostat, and Facebook.
Sensors designed for applications in consumer IoT applications will face serious demands for minimizing
size, power consumption, and especially price. Traditional mechanical and even MEMS based
technology may not be able to achieve these requirements, opening the door to fully printable sensors.
There is much work to be done, but the ability to simply print sensor circuitry on flexible film is highly
9 -2
attractive. Roll-to-roll processing can be extremely cost effective in high volume, but will require the
development of new conductive inks that can be printed in high deposit thicknesses and cure instantly.
Some applications will require printed conductors that can withstand constant flexing and feature self-
healing of fractured conductors. Connector manufacturers that have extensive flexible etched circuitry
expertise may have a head-start in this arena.
A sensor module that that can be manufactured inexpensively is the

focus of a development effort to design a tiny device that integrates
five sensors including humidity, CO2, acetone, ammonia, and
isoprene. The objective is to provide rescue workers a tool that
detects certain chemicals given off by the human body. Rescue
workers, each equipped with this sensor would be able to locate
people trapped in collapsed buildings quicker than using a limited
number of trained dogs.
Recognizing that software will play a critical role in the successful integration of sensors, General Electric
has opened a new software development center in San Ramon California with a staff of 1400
employees. The objective is to create a new operating system designed specifically for industrial
equipment and factory automation applications. This platform will meld the advantages of low-cost
sensors, powerful computers, and clever software to support the Industrial IoT. This system is expected
to be capable of managing 100 times more data in order to optimize production efficiencies while
reducing cost. GE sees the generation of real-time data and analytics as the keys to driving next
generation manufacturing systems.
Rapidly evolving markets and product technology is overhauling the traditional mix of competitors vying
for position in every industry. GE has traditionally been in competition with Rockwell Automation,
Siemens, and United Technologies, but is now facing new contenders such as IBM, Google, and
Microsoft who bring entirely new technology and expertise to the market. ON Semiconductor a major
supplier of ambient light sensors, proximity sensors, touch sensors, CCD and CMOS image sensors,
announced the opening of two design centers to expand their sensor product support of autonomous
driving technology. They recently purchased Truesense Inc., the former Kodak image sensor business
along with an Israeli millimeter-wave radar design center it acquired from IBM. Companies that see new
business opportunities are building their portfolio of resources through acquisition in order to speed the
introduction of new technology. This transformation of the electronics landscape will likely accelerate
ongoing industry consolidation as well as create new competitive players in established markets.
Honeywell announced a new line of self-diagnosing sensors designed to improve the performance and
reliability of sensors used in aircraft applications. Their Integral Health Monitoring series of proximity
sensors can detect a number of internal failures and display a fault warning to the pilot or maintenance
worker. The ability of sensors to incorporate features of self-diagnosis or self-calibration is highly
attractive in applications that involve critical systems in aviation, instrumentation, and medical
applications. As costs go down, this capability could find use in autonomous transportation.
Industry consolidation and acquisition appear to be continuing trends in the electronic sensor industry.
The majority of sensor manufacturing resources currently being marketed by connector companies have
9 -3
been acquired through purchase of smaller sensor manufacturers. In addition to limited outright
purchase, Molex has approached the sensor market by setting up Molex Ventures LLC, a wholly owned
subsidiary dedicated to solving industry challenges via investments in and collaborations with startup
companies that can leverage Molex design and manufacturing capabilities. The announcement of this
venture group listed potential strategic investments in medical and pharmaceutical sensors, connected
health, automotive mobility, Industry 4.0 sensors, and robotics.
The manufacture of sensors is a global business and not predominately located in one country or region
of the world. Large, medium, and small sensor manufacturers are distributed globally. Even when
acquired by a larger company, the purchased supplier often remains in place. Smaller suppliers are
expected to remain the primary target when larger suppliers need to add to their sensing product
portfolio.
The important role that sensors play in equipment now and in the near future is being recognized as
more technical papers are published and symposiums are becoming available. A three-day Sensors Expo
and Conference has been scheduled in San Jose CA on June 26-28, 2018 and will feature 10 technical
tracks with over 60 sessions conducted by 100 industry leaders. Topics to be discussed include energy
harvesting power solutions, Industrial IoT, medical sensor design, autonomous vehicles, and
printed/flexible/stretchable fabric sensors. A two day Sensors & Instrumentation exposition is
scheduled for September 25-26, 2018 in Birmingham UK, and will include an extensive series of seminars
on sensors and evolving applications. MEMS Journal, a weekly newsletter with a circulation of nearly
35,000 subscribers features multiple articles focused on new sensors and their application.
Short range wireless connectivity is becoming an important attribute for sensor modules. Modules now
on the market feature integrated, Bluetooth, ZigBee, ANT+, and Z-Wave and Wi-Fi radios. When
continuous stream of sensing data is not required, RFID can dump data on demand while requiring no
external power source.
Sensors are appearing in unexpected places. From baby mattress pads that monitor breathing patterns
and sends alerts of irregularities to your smart phone to the NASA Space Debris Sensor which is an
impact detector that is mounted on the exterior of the International Space Station that monitors
impacts caused by small-scale space debris. The march of new sensor applications promises
economically feasible capabilities never before possible. A good example is the LEONOQ intelligent
cable system. This developmental technology embeds a series of wireless sensors into the jacket of a
power or data cable. This system is said to record multiple parameters including temperature,
impermeability, mechanical stress, and GPS location factors that can portend future cable failure. In this
case the interconnect itself becomes intelligent.
9 -4
Micro-Electromechanical Systems Issues

Mems sensors are emerging as a preferred technology in terms of packaging density, sensing diversity
and low power consumption. The ability to integrate multiple MEMS sensors into one module supports
the rising interest in the advantages of sensor fusion, especially as customers demand unique
combinations of sensing functions. Applications in harsh environments especially extreme temperature
or vibration can impact the performance of MEMS sensors making them more prone to failure of
inaccurate output.
The extremely low power demands of passive MEMS sensors will enable a new breed of sensing devices
that are able to wake up a processor when a specific parameter such as a temperature or humidity point
is reached. These event-driven devices consume a few picowatts of power that could be provided by
piezo or ambient RF energy harvesting. Silicon based sensors will continue to dominate well into the
future, but research is underway to find lower cost materials that could be used to fabricate sensors in
disposable devices. Sensors that can operate successfully using locally harvested energy will open
entirely new applications. Sensors have demonstrated the ability to operate using energy generated
from solar cells, vibration, mechanical movement, and ambient RF energy.
Packaging of MEMS sensors is becoming a major focus in new applications where integration of an
accelerometer, magnetometer, gyroscope, and controller in the same package is required. Packaging
may be fully enclosed or open cavity where the sensing element must be exposed directly to the
parameter to be measured. In addition to multiple sensors, new packages may include CMOS logic,
memory, thin-film battery, Bluetooth radio, and antenna. This is being accomplished through stacked or
side-by-side die on a common substrate. The system in package (SIP) approach is becoming more
popular and is being driven by wearables and medical applications. More advanced packages have
begun using through silicon via technology.
The next iteration of MEMS technology is Nanoelectromechanical systems (NEMS) to further reduce the
size of the sensing module. Sensors built on the scale of individual atoms will improve the accuracy of
current systems, particularly in the measurement of extremely small quantities. They will offer
increased computational power combined with the ability to digest high-speed data generated by a
greater number of integrated sensors. NEMS-based sensors will also offer significantly reduced power
consumption, a major advantage as systems continue to shrink. Sensors that achieve this level of
density will require extensive signal conditioning and noise filtering capabilities. Sensors based on NEMS
technology are expected to experience exceptionally high growth rates as technical challenges related to
manufacturing and consistency are resolved.
One forecast calls for up to one trillion sensing units to be installed over the next 10 years.
9 -5
Internet of Things
The consumer electronics show is the annual extravaganza of the latest and greatest innovation applied
to electronic devices some of which go on to forming a new class of product, while others are never
seen again. Devices designed for the IoT have been a main focus of this show for years. A predominate
theme in the 2018 edition was sensing and featured a myriad of new IoT enabled devices. Unlike past
years, many of these new products featured higher performance sensors that enabled more useful
devices. Applications that ranged from a miniature drone embedded with six lidars, a camera and radar
that enables the drone to have 360° perception, to Buddy, a robotic personal companion that sports
three cameras and an array of sensors that enable him to learn from his environment.
Ultra low power, short range radio technology is expected to play a major role in the expansion of the
IoT. Applications in wearable medical, fitness, and home automation will rely on low energy
communication systems. Commercial applications including intelligent factories, smart grids, and smart
buildings will drive demand for sensors that are able to operate using long-life batteries and eventually
locally harvested energy.
The IoT is evolving into the Internet of everything. Key growth applications are crossing nearly every
market segment. Applications in automotive, medical, robotics, industrial control, and military will all
utilize the IoT to communicate. This convergence will drive demand for new non-proprietary
communication protocols for sensors that will enable a common framework for interoperability. Once
devices are speaking a common language, machines will be able to share information globally opening
an entirely new generation of automation. It will also mandate the deployment of data security
measures at a much higher level than exists today.
The marriage between LED lighting and sensors was

apparent at the LightFair International show recently held in
Chicago. Sensors that detect the presence of people and
cars, their speed as well as direction of travel are opening
the potential for networks of street lights that light the path
of oncoming vehicles and pedestrians, and then turn off,
saving energy. Enlighted offers a software-defined smart
sensor that collects and monitors real-time occupancy, light
levels, temperatures and energy usage. These sensors can
distinguish between people and objects and combine five
sensors (temperature, light level, motion and energy usage)
in one. Data is transferred via Bluetooth to a gateway and
energy management system for analysis and management.
Several futurists have predicted the rise of “sensor swarms” consisting of billions of heterogeneous
sensors that will eventually become the successor to the IoT. Extremely inexpensive and ubiquitous
MEMS sensors will make almost everything “smart”.
9 -6
Artificial Intelligence
The topic of artificial intelligence (AI) appears of be popping up in every corner of the industry, but is far
from even beginning to have a major impact on our lives….yet. AI is coming of age driven by the
convergence of advanced machine learning algorithms, access to nearly unlimited information via the
Internet, and supercharged computing power. Data generated by a network of sensors provides the
input used by algorithms that enable machine learning. The result is the ability for AI to make better
choices and more efficient automated systems. The synergy between sensors and AI allow it to analyze
large blocks of data, from multiple sources to reveal patterns and provide insight that ultimately allow it
to make informed decisions.
One example of AI in use today uses sensors to gather data from consumer devices such as
smartphones. Motion sensors and GPS location sensors have been deployed in retail stores to increase
customer engagement, and potentially match customer profile and experience with pricing structures.
Cameras equipped with facial recognition software can recognize a return customer and alert a clerk for
immediate attention. Some customers may object to the amount of personal information the store is
able to access, but it can be used to provide more targeted advertising. The result would be fewer ads
promoting hoverboards to seniors. Retail stores are looking for tools by which they can combat on-line
sales and improve the personal customer experience.
Nvidia is known for its line of high-performance graphics processing units designed for the gaming
industry. They have also become a leader in powering autonomous transportation systems. The DRIVE
IX technology combines data from a network of internal and external sensors to provide AI assistant
convenience features and co-pilot safety features. Sensors track driver head movements to detect
distractions, and are able to conduct verbal conversations using speech recognition and lip reading
sensors. The vehicle can be unlocked using facial recognition and set personal preferences with simple
gestures.
In order for AI to function, it requires access to extensive information about the physical world. Sensors
are the channel by which AI learns about the environment. Infrared cameras allow AI systems to
visualize what humans cannot see, while other sensors are able to detect frequencies we cannot hear.
3D imaging sensors allow devices such as robots to analyze obstacles while navigating among a crowd of
humans. AI can use this 3D data to anticipate movement and chart a safe course. Gesture recognition as
a user interface is another application for 3D sensors. The majority of smartphones already incorporate
3D sensors.
3D sensors are not limited to traditional optical sensing. Vayyar, based in Israel has introduced 3D
sensors that utilize RF energy to generate high resolution images through solid materials. The chip
generates imaging and radar bands with 72 transmitters and 72 receivers. Enhanced by an integrated
high-performance DSP chip and a large internal memory it is able to create images that penetrate walls
or human tissue.
Google has demonstrated the power of AI with the ability to correctly identify specific objects within the
frame of a smartphone image. The camera essentially becomes a virtual super sensor. Applying this
technology, the concept of deploying billions of single-purpose sensors could be made obsolete by the
9 -7
rise of what has been dubbed the virtual sensor. This “universal” sensor would incorporate a group of
sensors commonly used in home or industry. Simply plugged in, the sensor would be programmed to
detect, interpret, and report desired information. This software defined sensor could be standardized
and produced in very high volume to minimize cost. Much like the desktop MakerBot 3D printer, or the
smartphone app store, availability of a library of software programs would allow the average consumer
to configure and customize a system to meet specific needs.
9 -8
Sensors in Medical and Wearable Applications

At least four technologies are converging to enable a proliferation of sensor based applications in
medical and wearable electronic devices. Certainly, the miniaturization of electronics allows more
functionality in smaller and lighter packages. System on package and system on chip technology are
packing multiple functions on a single chip that consumes much less power. MEMS based sensors have
opened the door to the ability to sense temperature, humidity, blood pressure, and respiration rate
using a single package.
Advanced rechargeable batteries are now thin and
flexible making them easier to integrate into
clothing. In addition to Bluetooth wireless
communication, additional protocols allow a
designer to choose a wireless radio with range and
data rate that closely matches the requirement of
the specific application. Finally, advances in
microfluidics are making complex “lab-on-a-chip”
devices possible. Research being done at Stanford
University has resulted in a low-cost re-useable
diagnostic chip created by using an ordinary ink-jet
printer. With a target price of $.01 each, the chip
uses a combination of microfluidics, conductive nanoparticle ink, and electronics. The result is a module
that can enable counting of blood cells. Applying an electric potential, a process called
dielectrophoresis, single cells can be isolated for analysis. This technology can be applied in developing
countries where health care resources are limited as well as in laboratories to speed up research.
Organs-on-chips are microfluidic cell cultures that simulate

the function of biologic organs and are used to evaluate
response to medications, cosmetics, foods, and therapies.
ORCHID, a European initiative is a consortium of academic and
private partners that are actively developing organs-on-chips
which combine human mini-organs with microelectronics,
microfluidics, and nanosensors. This technology would be a
vast improvement over traditional cell culture and animal-
based test methods.
Scientists in Taiwan have developed a low-cost handheld

biosensor that can analyze a drop of blood to determine the
level of C-reactive protein in the bloodstream. High levels
have been related to increased risk of heart attack. Changing
the chemical receptors used in the device could test the blood for additional conditions. A wireless
connection to a smartphone application could record readings and send flash warnings if limited are
exceeded.
A recent article in the Wall Street Journal highlighted advances in wearable health care devices
including;
9 -9
• Remote monitors that consist of tiny adhesive patches that are loaded with sensors and
electronics that measure vibrations created by body organs such as the opening and closing of
heart valves, vocal chords and gastrointestinal tract as well as heartbeat. Artificial intelligence
analyzes the input and looks for anomalies. Wirelessly linked to a smart phone, a doctor can
monitor activity anywhere in the world.
• A knee brace that utilizes a series of gears connected to a DC generator. Walking or running
converts movement to electrical energy that can be used to charge portable electronics.
• E-skin, now in development is a thin, translucent

and supple material that can mimic the function and
mechanical properties of human skin. One version in
development at the University of Colorado, Boulder has
embedded sensors to measure pressure, temperature,
humidity, and air flow. This material is self healing and fully
recyclable. E-skin is finding applications in artificial limbs,
robotics as well as long-term health monitoring systems.
• Accurately measuring the quality of sleep typically requires the attachment of 10-15 wired
electrodes which themselves can make sleep difficult. Work is being done to design a simple
sensor placed in the ear that can be used to measure and record EEG patterns.
Research continues on ways to integrate electronic

circuits adjacent to or directly in contact with the
skin. A new category of electronic circuit materials
enables stretchable and conformable electronics.
Rather than integrating standard, typically ridged
components, new generations of sensors, batteries,
displays and interconnects are designed for
attachment to flexible substrates. Stretchable
conductive inks can be applied using conventional
ink jet printers or fine metal conductors can be
embedded in the stretchable substrate. The result can be unobtrusive electronic devices that can be
worn for extended periods.
9 -10
Electronic circuits and components applied directly to the

skin is another approach. A 3D printer has already proven
the feasibility of this technology. Initial tests involve
printed circuitry and placement of discrete components,
but developers anticipate the ability to print batteries,
solar cells as well as passive components.
A key enabler of many portable medical devices is the continuing advances in microprocessors and
wireless radios that consume incredibly low amounts of power. Software that puts the system into a
sleep mode except for very short scheduled periods of transmission or only when new data is received
keep power consumption to an absolute minimum. At the same time new variations of Lithium-ion
batteries are improving energy density, number of charge/discharge cycles, increased internal resistance
as well as safety. Batteries are becoming smaller and flexible enough to fit in tight spaces. Next
generation battery chemistries are expected to utilize anodes composed of nanoparticles with a hard
graphite-silicon shell resulting in a 20% to 40% improvement in storage capacity.
9 -11
Robotics
A new initiative named Farm View intends to
improve the way we grow food in order to
meet the needs of a growing world
population. Deploying fleets of mobile field
agribots equipped with an array of sensors
and using artificial intelligence will make
possible smarter and more productive land
use. These robots will use multiple sensors to
gather highly detailed information on soil
types and moisture levels that allow farmers
to make more efficient crop choices with higher yields and quality while using the land and water
resources more efficiently. These agribots make it possible to analyze and map soil quality in real time
which would determine the best time to plant as well as precise application of fertilizer and irrigation
according to the specific needs of each area.
An extensive array of location, touch,

chemical analysis, and navigation sensors
allow the robots to autonomously
navigate fields while avoiding crops. In
orchards a robot can measure tree canopy
to determine the extent of pruning
necessary to maximize crop yield. Robots
fitted with highly specialized tools will be
able to prune trees as well as pick fruit.
Research is well underway that will result
in robotic arms with sensors capable of
measuring the ripeness of the fruit.
Great progress has been made in developing robots that are designed to work directly with humans.
In the past, industrial robots were isolated from humans as their rapid movements, strength and
inability to recognize and avoid people in the area, posed a serious safety threat. Newer machines
outfitted with multiple sensors and advanced machine learning have been designed to directly assist
humans. A robot undergoes a training period where a series of scenarios and even social norms are
simulated. This gives the robot the basic skills needed to navigate a crowed sidewalk. A bank of sensors
provides the robot a real time view of its immediate environment ten times a second. The result is a
robot that can move freely among people.
Amazon utilizes a fleet of robots in their network of fulfillment centers to fetch and deliver product to
human shippers. Utilizing these robotic pods allows Amazon to constantly reduce delivery time and
cost. This new breed of lower cost collaborative machines is being adopted by many smaller companies
that can take advantage of the increased productivity that robotics offer.
9 -12
The current process of programming a robot is a significant

limitation to wider adoption. Programming language has
been simplified, but still requires a degree of skill. The
problem is finding a way to communicate with a robot
directly. Nvidia has recently demonstrated an
experimental system that uses neural networks and video
imaging to visually train a robot. A camera “watches” a
human perform a new task. The system analyzes the
sequence, determines the actions required to duplicate
what it had “seen”, and then performs the task. The
ultimate goal of designers is for robots to learn from verbal
instructions, and then share a task among other robots
with different skills.
Demographics in developed economies are providing a
strong indicator that robotic devices of all types will be
playing an increasing role in our daily life. Japan with its
aging human workforce is leading the pack in deploying
robotics in everything from robotic milking machines to personal companions for seniors. It is unclear
how the potential conflict of manual jobs lost to automation and people that do not have specific skills
will play out, but the economic advantages of robots that employ a host of sensors points to continuing
growth of robotic devices.
Robots have typically been perceived as mechanical devices with a central “brain” that controls all
aspects of how the robot behaves. Work is being done on the possibility that intelligence can be
distributed throughout the robot using advanced materials that can sense, compute, actuate, and
communicate independent of the central computer. Such a device for instance would utilize pressure
sensitive grippers that can sense the type of object and immediately limit the force applied to what is
necessary to pick the item up without damage. Computations at this local level frees up the central
processor for more rigorous duty in navigation or task management. In one sense this is much like the
concept of central vs. distributed computing where simple tasks are managed locally, freeing up data
center servers as well as reducing latency.
9 -13
Chapter 10
Chapter 10 Sensor Market Values and Forecasts

Introduction
Bishop and Associates has been tracking the electronic connector industry for nearly 33 years. Over that
period we have established a roster of high-level contacts among industry leaders as well as built a
detailed database that we use to estimate connector market values by type, industry and region of the
world. Years of experience have enabled us to evolve a process to create highly accurate forecasts and
five year compound average growth rate (CAGR) estimates.
This report on electronic sensors is a major departure from our core area of focus and presented a
significant challenge in quantifying market values and generating credible forecasts. As reported in the
text, the universe of sensor manufacturers is highly splintered with relatively few very large sensor
manufacturers, and a large number of mid-sized and smaller suppliers. In some instances such as Texas
Instruments and STMicroelectronics, sensors are one part of a broad line of semiconductor devices.
Other major suppliers such as Robert Bosch GmbH offer sensors as only one niche of a much broader
product line that range from commercial building HVAC applications to food processing and packaging
equipment. Unlike the electronic connector industry where the largest suppliers are concentrated in
relatively few countries, leading sensor suppliers are scattered around the world. Another complicating
factor is that medium and small sensor manufacturers tend to focus their products in support of specific
markets or even individual applications such as magnetic sensors used in automotive applications or
vibration sensors to detect impending failure of industrial process equipment. Highly specialized
sensors designed for military and aerospace applications fit into another unique niche. All of these
factors make the process of determining accurate sensor market estimates and forecasts less than
precise.
The primary objective of this report is to identify the factors that have encouraged several leading
connector manufacturers to expand their commitment to electronic sensors, and in the process, expand
their total available market. We have chosen to document the entire electronic sensor industry rather
than concentrate on a specific segment or type of sensor. Large connector manufacturers such as
Amphenol and TE Connectivity have assembled a broad sensor offering that serves markets that range
from consumer products to avionics, with emphasis on sensors that can survive rough environments or
require extensive design support. This meshes well with their overall corporate emphasis on ruggedized
connectors.
It is entirely possible for a sensor to be specified by an OEM located in the United States, procured by an
offshore manufacturing site, or contract manufacturer from a local distributor and actually assembled
into a product by a subcontractor. For purposes of this report, we attribute sales to the region of the
world where the sensor is implemented into a final product.
Charts that define the technologies employed by sensors include “all others”. That category
encompasses piezoelectric, capacitive, inductive, thermoelectric and Hall Effect.
All market values are expressed in US dollars.
10 -1
We estimate the total global market for electronic sensors reached $95.2 billion in 2017, and will grow
to $168.8 billion by 2023.
Total World Sensor Sales

2017 through 2023F
10 -2
Total World Sensor Sales by Region

2017, 2018F, and 2023 with 5-Year CAGR
5-Year
Region 2017 2018F % Change 2023F CAGR
North America $19.6 $21.5 9.9% $32.5 8.6%
Europe $19.5 $22.0 13.0% $33.5 8.8%
Japan $7.8 $8.5 9.6% $11.9 7.0%
China $30.2 $34.5 14.1% $59.6 11.6%
Asia Pacific $13.8 $15.4 11.4% $24.0 9.3%
ROW $4.3 $4.9 13.2% $7.3 8.3%
Total World $95.2 $106.8 12.2% $168.8 9.6%
$ Billions
Total World Sensor Market by Region

Ranked by 5-Year CAGR
2018F to 2023F
10 -3

2017 through 2023F
With Percent Change and 5-Year CAGR
Percent Percent Percent

Region 2017 2018F Change 2019F Change 2020F Change
North America $19.6 $21.5 9.9% $23.1 7.3% $25.2 9.1%
Europe $19.5 $22.0 13.0% $23.7 7.7% $25.4 7.2%
Japan $7.8 $8.5 9.6% $9.0 5.7% $9.6 6.7%
China $30.2 $34.5 14.1% $37.8 9.7% $42.2 11.6%
Asia Pacific $13.8 $15.4 11.4% $16.7 8.4% $18.0 7.8%
ROW $4.3 $4.9 13.2% $5.2 6.1% $5.7 9.6%
Total World $95.2 $106.8 12.2% $115.5 8.1% $126.1 9.2%
$ Billions
Percent Percent Percent 5-Year

Region 2021F Change 2022F Change 2023F Change CAGR
North America $26.8 6.3% $29.0 8.2% $32.5 12.1% 8.6%
Europe $27.2 7.1% $29.6 8.8% $33.5 13.2% 8.8%
Japan $10.2 6.3% $10.9 6.9% $11.9 9.6% 7.0%
China $46.7 10.7% $52.6 12.6% $59.6 13.3% 11.6%
Asia Pacific $19.2 6.7% $21.1 9.9% $24.0 13.7% 9.3%
ROW $6.1 7.0% $6.6 8.2% $7.3 10.6% 8.3%
Total World $136.2 8.0% $149.8 10.0% $168.8 12.7% 9.6%
$ Billions
10 -4

Percent Market Share by Region
2017 through 2023F
Region 2017 2018F 2019F 2020F 2021F 2022F 2023F

North America 20.6% 20.2% 20.0% 20.0% 19.7% 19.4% 19.2%
Europe 20.5% 20.6% 20.5% 20.1% 20.0% 19.8% 19.8%
Japan 8.2% 8.0% 7.8% 7.6% 7.5% 7.3% 7.1%
China 31.7% 32.3% 32.7% 33.5% 34.3% 35.1% 35.3%
Asia Pacific 14.5% 14.4% 14.5% 14.3% 14.1% 14.1% 14.2%
ROW 4.5% 4.6% 4.5% 4.5% 4.5% 4.4% 4.3%
Total World 100.0% 100.0% 100.0% 100.0% 100.0% 100.0% 100.0%

Percent Market Share
2017 through 2023F
10 -5
2018F Sensor Sales

2023F Sensor Sales

Percent 5-Year
Market Sector 2017 2018F Change 2023F CAGR
Automotive $22.4 $25.0 10.3% $40.1 9.9%
Consumer $17.4 $19.7 11.5% $34.2 11.6%
Industrial $23.8 $26.6 11.8% $42.5 9.8%
Medical $6.0 $6.9 15.0% $11.0 9.8%
Military $3.2 $3.7 14.4% $5.0 6.2%
Telecom $11.6 $12.9 11.1% $17.9 6.8%
Transportation $6.7 $7.5 12.1% $11.3 8.6%
All Other $4.1 $4.5 9.9% $6.8 8.6%
Total World $95.2 $106.8 11.5% $168.8 9.6%
$ Billions
10 -6
Total World Sensor Sales by Equipment Sector

2017, 2018F, and 2023 with 5-Year CAGR
Percent 5-Year
Market Sector 2017 2018F Change 2023F CAGR
Automotive $22.4 $25.0 10.3% $40.1 9.9%
Consumer $17.4 $19.7 11.5% $34.2 11.6%
Industrial $23.8 $26.6 11.8% $42.5 9.8%
Medical $6.0 $6.9 15.0% $11.0 9.8%
Military $3.2 $3.7 14.4% $5.0 6.2%
Telecom $11.6 $12.9 11.1% $17.9 6.8%
Transportation $6.7 $7.5 12.1% $11.3 8.6%
All Other $4.1 $4.5 9.9% $6.8 8.6%
Total World $95.2 $106.8 11.5% $168.8 9.6%
$ Billions
Total World Sensor Market by Equipment Sector

Ranked by 5-Year CAGR
2018F to 2023F
10 -7

2017 through 2023F
With Percent Change and 5-Year CAGR
Percent Percent Percent

Market Sector 2017 2018F Change 2019F Change 2020F Change
Automotive $22.4 $25.0 11.7% $27.0 8.0% $29.4 8.9%
Consumer $17.4 $19.7 13.2% $21.7 10.0% $24.0 10.6%
Industrial $23.8 $26.6 11.8% $28.7 7.9% $31.4 9.4%
Medical $6.0 $6.9 15.0% $7.5 8.7% $8.2 9.3%
Military $3.2 $3.7 14.4% $3.9 5.3% $4.2 7.7%
Telecom $11.6 $12.9 11.1% $13.9 7.8% $14.9 7.2%
Transportation $6.7 $7.5 12.1% $8.0 7.1% $8.8 10.0%
All Other $4.1 $4.5 9.9% $4.8 6.7% $5.2 8.3%
Total World $95.2 $106.8 12.2% $115.5 8.2% $126.1 9.2%
$ Billions
Percent Percent Percent 5-Year

Market Sector 2021F Change 2022F Change 2023F Change CAGR
Automotive $31.8 8.2% $35.1 10.4% $40.1 14.2% 9.9%
Consumer $26.1 8.8% $29.3 12.3% $34.2 16.8% 11.6%
Industrial $34.1 8.6% $37.5 10.0% $42.5 13.3% 9.8%
Medical $8.9 8.5% $9.8 10.1% $11.0 12.2% 9.8%
Military $4.4 4.8% $4.7 6.8% $5.0 6.4% 6.2%
Telecom $15.8 6.0% $16.9 7.0% $17.9 5.9% 6.8%
Transportation $9.5 8.0% $10.4 9.5% $11.3 8.7% 8.6%
All Other $5.6 7.7% $6.1 8.9% $6.8 11.5% 8.6%
Total World $136.2 8.0% $149.8 10.0% $168.8 12.7% 9.5%
$ Billions
10 -8

Percent Market Share by Equipment Sector
2017 through 2023F
Market Sector 2017 2018F 2019F 2020F 2021F 2022F 2023F

Automotive 23.5% 23.4% 23.4% 23.3% 23.3% 23.4% 23.8%
Consumer 18.3% 18.5% 18.8% 19.0% 19.2% 19.6% 20.3%
Industrial 25.0% 24.9% 24.8% 24.9% 25.0% 25.0% 25.2%
Medical 6.3% 6.5% 6.5% 6.5% 6.5% 6.5% 6.5%
Military 3.4% 3.5% 3.4% 3.3% 3.2% 3.1% 3.0%
Telecom 12.2% 12.1% 12.0% 11.8% 11.6% 11.3% 10.6%
Transportation 7.0% 7.0% 6.9% 7.0% 7.0% 6.9% 6.7%
All Other 4.3% 4.2% 4.2% 4.1% 4.1% 4.1% 4.0%
Total World 100.0% 100.0% 100.0% 100.0% 100.0% 100.0% 100.0%

Percent Market Share
2017 through 2023F
10 -9
2018F Sensor Sales

2023F Sensor Sales

10 -10
Total World Sensor Sales by Technology

2017, 2018F, and 2023F with 5-Year CAGR
Percent 5-Year
Technology 2017 2018F Change 2023F CAGR
MEMS 26.2% 28.8% 9.9% 27.2% -1.1%
NEMS 7.3% 7.5% 2.7% 25.4% 27.6%
CMOS 40.8% 41.4% 1.5% 36.6% -2.4%

Other 25.7% 22.3% -13.2% 10.8% -13.5%
Total World 100.0% 100.0% 100.0%
2018F Total World Sensor Sales

by Technology
10 -11
2023F Total World Sensor Sales

by Technology
MEMS Sensor Technology Sales by Equipment Sector

Percent 5-Year
MEMS by Sector 2017 2018F Change 2023F CAGR
Automotive 14.0% 14.1% 0.7% 16.5% 3.2%
Consumer 22.2% 23.2% 4.5% 25.8% 2.1%
Industrial 8.4% 8.5% 1.2% 8.0% -1.2%
Medical 16.0% 16.1% 0.6% 18.0% 2.3%
Military 14.6% 14.4% -1.4% 14.0% -0.6%
Telecom 5.8% 5.3% -8.6% 4.3% -4.1%
Transportation 12.0% 12.4% 3.3% 11.4% -1.7%
All Other 7.0% 6.0% -14.3% 2.0% -19.7%
Total World 100.0% 100.0% 100.0%
10 -12
2018F MEMS Sensor Technology Market Share

by Equipment Sector
2023F MEMS Sensor Technology Market Share

by Equipment Sector
10 -13
NEMS Sensor Technology Sales by Equipment Sector

Percent 5-Year
NEMS by Sector 2017 2018F Change 2023F CAGR
Automotive 14.0% 13.7% -2.1% 17.2% 4.7%
Consumer 19.4% 17.0% -12.4% 17.6% 0.7%
Industrial 8.8% 8.8% 0.0% 8.0% -1.9%
Medical 18.2% 20.0% 9.9% 24.8% 4.4%
Military 15.8% 17.1% 8.2% 18.4% 1.5%
Telecom 6.2% 5.9% -4.8% 2.0% -19.5%
Transportation 12.6% 12.5% -0.8% 10.0% -4.4%
All Other 5.0% 5.0% 0.0% 2.0% -16.7%
Total World 100.0% 100.0% 100.0%
2018F NEMS Sensor Technology Market Share

by Equipment Sector
10 -14
2023F NEMS Sensor Technology Market Share

by Equipment Sector
CMOS Sensor Technology Sales by Equipment Sector

Percent 5-Year
CMOS by Sector 2017 2018F Change 2023F CAGR
Automotive 3.0% 3.1% 3.3% 14.8% 36.7%
Consumer 8.7% 9.0% 3.4% 20.3% 17.7%
Industrial 5.3% 5.5% 3.8% 8.0% 7.8%
Medical 8.0% 8.6% 7.5% 8.9% 0.7%
Military 5.0% 5.3% 6.0% 2.0% -17.7%
Telecom 63.7% 62.0% -2.7% 42.0% -7.5%
Transportation 4.0% 4.3% 7.5% 2.0% -14.2%
All Other 2.3% 2.2% -4.3% 2.0% -1.9%
Total World 100.0% 100.0% 100.0%
10 -15
2018F CMOS Sensor Technology Market Share

by Equipment Sector
2023F CMOS Sensor Technology Market Share

by Equipment Sector
10 -16
Chapter 11
Chapter 11 Major Findings and Conclusions

Introduction
There is little doubt that we are at the cusp of a major revolution in how the world will get things done
in the future. Entire industries have been shaken to their roots as they watch new technologies
marginalize what had been their flagship products.
History has been littered with companies that were
not able to adapt to the emergence of new disruptive
technologies. Videotape was replaced by the CD,
which is now being replaced by streaming video.
Kodak never recovered from their failure to recognize
the impact that digital imaging would have on their
film business. Dentists have replaced traditional bite-
wing X-ray film with electronic X-ray sensors that
instantly generate images with higher resolution.
Touch-pads control everything from imputing credit
card data at the gas station to your home microwave
oven. These changes are pervading every aspect of our life. The pace of these changes has been
accelerating.
The evolution from the first computers, to the smartphone of today brought access to incredible
computing power to the individual. Earlier generations of computers were unable to make sense of
terabits of data, but massive data centers that combine the computing power of tens of thousands of
servers linked together can feed this information stream to advanced algorithms to make intelligent
choices and take action. We are now beginning to see what the fruits of that computing power
combined with artificial intelligence and machine learning can produce. Devices equipped with machine
learning require information about a process or system as well as the environment in which it performs
before it can begin analyzing and making improvements in an existing process. The Internet is
becoming the input channel for the vast amounts of data required for artificial intelligence to function.
The source of much of that data will be via billions of sensors linked to the Internet. Sensors provide
that key function of allowing direct communication between humans and machines as well as machine
to machine.
Key Points
We now live in a data driven economy. A universe of sensors is generating a big portion of that data.
Sensors detect the current state of a specific environment and produce a representative analog or
digital output signal. Actuators produce motion or cause action based on the input from sensors.
Sensors of all types can collect information about our physical world and convert it into a form that
computers are able to recognize, analyze, and act on. Applications that range from the pluggable
automotive module that tracks speed, acceleration, and inertia of every car to the guidance systems
used in space probes have made sensors an essential component. The Internet of Things is only one
aspect of multiple technologies that will generate demand for billions of sensors that will touch every
aspect of our life. Automation of transportation, medical diagnostics and treatment, industrial process
11 -1
control as well as home automation will require huge networks of connected sensors. Increasing
demand for new technology drivers now includes artificial intelligence, machine learning, advanced
processors and software, making data input from a universe of sensors key to our future. The
logarithmic expansion of the electronic sensor market makes it a highly attractive target for any
company seeking new avenues of long-term growth.
Leading connector manufacturers have realized that the connector industry may have exhausted its
ability to maintain historical growth and profitability rates within the electronic connector space and are
looking beyond their traditional interconnect world. Many suppliers expressed the opinion that they
see sensors as a logical extension of connectors that expands the meaning of connectivity. Wherever
there is a sensor, there is an output signal that typically passes through a connector somewhere in the
system. The industry has evolved from simply supplying connectors to providing connectivity
throughout the system, including from sensor to actuator.
Connector manufacturers would like to increase their value-added proposition, but moving higher in the
product chain to a system level could cause conflict with their current OEM customers. Several large
suppliers that are feeling this growth limitation see electronic sensors as a logical choice of related
component in which to invest. Products such as personal computers that had been the component
revenue growth leader for years have been in decline and even smartphones have begun to reach a
saturation point. Software enables what at one time required multiple devices, resulting in reduced
device sales.
The global connector market reached over $60 billion in 2017 with a five-year compound average
growth (CAGR) of 6.8%, while we estimate the global market for sensors in 2017 reached $95.2 billion
with a five year CAGR of 9.6%. China was credited as the largest market for electronic sensors in 2017,
and is expected to remain the frontrunner for at least the next five years.
Entering the sensor industry opens broad new opportunities for major connector manufacturers by
increasing total available market. Large connector manufacturers can leverage their positive reputation,
established customer relationships, extensive technical expertise, financial resources, existing
manufacturing capabilities, and global infrastructure to bring value. Connector manufacturers may have
well established products such as flex film circuits, packaging expertise, and micro antennas that can
complement the sale of sensors. The sensor industry is highly fractured consisting of a few very large
suppliers, hundreds of mid-range manufacturers and thousands of small, sometimes specialty
manufacturers. The sensor industry is further segmented by suppliers that focus their products on a
specific industry or application, type of sensing technology utilized or the fabrication of custom sensors.
This proliferation of sensor manufacturers has made the acquisition of sensor companies an efficient
process by which to quickly build a focused or broad sensor product line. From a connector
manufacturer’s perspective the ideal mix of sensors are those that require extensive engineering
support and represent mid-range to relatively low production volumes. Most connector manufacturers
will want to avoid sensors that are or will soon become commodity products. Price erosion of many
high volume sensors is being driven by semiconductor manufacturers that profit by expanding their
semiconductor wafer output.
Sensors and connector markets in many ways are complementary. Electronic sensors, especially higher-
11 -2
performance sensors, often feature an integrated connector or are attached to a separable cable
assembly. Industrial automation applications typically use M5, M8, M10.5, M12, and M20 shielded
circular connectors for connection to sensors and actuators. Amphenol and Molex offer a complete line
of M connectors to support the design-in process of a sensor. TE Connectivity offers M8 and M12 field-
installable connectors. The streams of data that networks of sensors generate will require ever more
communication networks and more powerful computing and storage infrastructure, all of which utilize
connectors. Design engineers who specify connectors may be different than those that select sensors,
but both are often part of the same component engineering and design team. OEM management often
tries to minimize the number of vendors they must work with. A large global supplier that offers
connectors and sensors as well as technical support for both can deepen the long-term relationship and
open the door to potentially better pricing based on total volume. A global supplier may also have
internal technical and financial resources that can be applied to the development of a new sensor.
There are at least 48 different types of sensors available today, with the likelihood that many more will
be introduced over the next few years. Sensors fall into the two basic categories of active and passive.
They differ widely in the technology applied, form factor, connection method, durability, stability,
reliability, accuracy, and price. Sensors may produce an analog or digital output and may be designed
for direct exposure to the condition being measured or feature non-contact measurement. Sensors can
be soldered directly to a PCB, terminated with discrete wires, configured with an integrated pluggable
connector or utilize wireless connectivity. Prices of individual sensors can vary between a few cents and
hundreds of dollars. Sensors live in the real world, exposing them to a host of harsh environments,
making durability and reliability prime concerns. Connector manufacturers that have chosen to
participate in the sensor market are focusing on highly engineered solutions that leverage their
extensive design, materials, manufacturing, and business relationship resources.
There has been some disappointment expressed about the rate of adoption of IoT applications as well as
the value some early manifestations bring to the market. The automated pet treat dispenser that is
controlled from a smart phone may not be much of a game changer, but more serious IoT enabled
products are beginning to demonstrate what IoT devices that feature integrated intelligence can bring to
the market. A recent example is a digital suspension system for automotive applications. ClearMotion
based in Boston, introduced an active motion control system that can instantly compensate for potholes
in road surfaces. Combining a series of accelerometers at each wheel with proprietary algorithms, this
proactive suspension system can pull the wheel up, rather than allow it to drop down into a pothole,
smoothing the ride. The car is able to sense and respond to road conditions in real time. In addition,
this system includes a form of machine learning to improve the ride over time, and also is capable of
collecting data on particularly poor areas and send alerts to local road maintenance departments. This
is the type of sensor enabled IoT application that brings real value to the consumer. It is a classic
example of what can result from the convergence of advanced software, actuators that can respond in
milliseconds to input from ruggedized sensors, and wireless transmission of information.
Sensors are increasingly being used to improve the performance of common products. The traditional
walking cane used by people with sight impairment has been the target of several design teams. The
WeWALK cane detects ground-level obstacles and head-level obstructions using ultrasound pings. The
user gets a warning buzz on the handle. The XploR cane uses video imaging technology to identify faces
from as far as 10 meters from a library of facial photos known to the user. Once a familiar face is
identified, the cane vibrates. MySmartCane is a 3D printed ball attached to a conventional cane that
11 -3
uses ultrasonic sensors to measure the distance to nearby objects.
The lack of general standards governing mechanical profiles and communication protocols has been
identified as a potential challenge in broad application of sensors. The unique role that sensors play in
electronic systems often makes them difficult to standardize. Communication protocols such as I²C are
widely used, but not universal. Other standards address EMC, test methods, and safety, but none that
address a broad range of equipment type or industry. There are special interest groups and consortiums
that are working on the development of standards, but they are mostly related to a specific industry.
The SOSA Consortium for instance is developing sensor standards and reference architectures designed
for use in military and commercial equipment. Interviews with leading sensor suppliers do not
anticipate a short-term resolution to the lack of standards. The design-in process of many sensors
continues to require extensive engineering support. Individual sensor manufacturers offer reference
designs and test-evaluation boards that speed the design-in of their products.
The markets mentioned as having the greatest growth potential over the next five years include
transportation, especially autonomous transportation, Internet of Things, Industrial Internet of Things
(Industry 4.0), and medical, especially wearable medical devices. Each of these categories brings their
own unique challenges that can benefit from a unified solution of sensor and connectivity. Devices
targeting transportation applications will require the ability to survive the under-hood environment with
a level of reliability that can be trusted in life-impacting situations; and at a low cost. IoT devices will
often require very low power and space, at commodity prices. Industry 4.0 will bring intelligence and
self diagnostics to the factory which makes rugged sensors a critical source of essential data. Medical
wearables require accurate sensors that are lightweight, unobtrusive, wirelessly connected and capable
of surviving regular laundering. The overall trend is a world that will be filled with many more sensors
including those that are employed in energy production and management, security and military
applications.
The trend toward the integration of multiple sensors, filters, microcontroller, and wireless transmitter is
picking up steam. Creating a network of hundreds or even thousands of independent sensors can add
complexity to a system. The challenge is developing a system that converts multiple streams of raw
data into useful information that can be acted on. Sensor fusion refers to the integration of multiple
sensors into a single, often custom package. The resulting data stream is fused using unique algorithms
to extract more useful information that can be applied to solve complex problems. Devices that
demonstrate sensor fusion can consist of simply more than one sensor, but those that collect data on
multiple parameters, and utilize on-board ability to analyze the results locally, save valuable space and
consume less power making them more efficient. These “smart” modules may consist of multiple
devices mounted on a small PCB, or consist of multiple chips integrated on a single substrate. These
system-on-package modules represent the next generation of electronic sensors. Low cost discrete
commodity sensors will continue to be utilized in high-volume consumer products, but many connector
and sensor suppliers are focusing on higher performance sensor solutions that command higher margin,
and offer better synergy to the connector side of the house. To a large degree, sensor manufacturers
differentiate their products on breadth of product lines, quality, technical support, and ultimately price.
Consolidation within the sensor industry has been an ongoing process, with established sensor suppliers
scooping up smaller shops in order to fill out their product lines. Connector manufacturers have also
11 -4
been actively picking up mid to large sensor suppliers in order to enter this market. In most cases,
connector manufactures have concentrated their acquisitions on sensor suppliers that compliment their
connector products. Amphenol for instance has a long history of providing commercial and military
connectors which is reflected in their lines of sensors. TE Connectivity has refocused their corporate
philosophy to concentrate on rugged connectors. Their movement into sensors includes both general as
well as sensors designed for harsh environments. Sensors by their nature are exposed to the physical
world, which of often harsh and demanding. Expertise developed over many years of designing rugged
connectors can be applied to sensors making the single source for both products the preferred choice.
There are many types of sensors that range from measuring temperature to sensing the direction of a
magnetic field. Within each category, several different technologies may be used to generate either an
analog or digital output. The physics applied to sensors from multiple suppliers may be the same, but
how they are packaged may be even more important. Sensor catalogs are full of custom variations of
physical shape, type of output, voltage ratings, response times, accuracy over time, and power
requirements. The ability to integrate multiple sensors along with appropriate amplifiers, filters, and
microprocessors is a prime method by which sensor manufacturers are able to differentiate their
products.
Artificial intelligence (Al) and machine learning will be playing increasingly important roles in the coming
years. To achieve their full potential both technologies will require information generated by a global
network of advanced sensors. Sensors embedded in military and aerospace applications transmit
multiple streams of high-speed data. The ability to make any sense of that much input requires the use
of Al. Sensors that integrate Al will use advanced algorithms to analyze the data and output a single
stream of useful data that can be acted on. Robotic machines today are limited by the software that
drives their abilities. The input process is improving, but still requires operator expertise or manual
“training”. Robots that take advantage of AI will sense verbal or video input in order to quickly learn
new tasks. AI will enable an entirely new class of consumer assistant devices that will take over
responsibility for many mundane household tasks. The use of Al comes with some serious legal and
moral questions. Applied in medical diagnostic applications, who will be responsible if AI makes the
wrong decision; programmers, a clinic, a manufacturer of a failed sensor, a doctor that accepts an
inaccurate AI diagnosis? It will be difficult to file a malpractice suit against a machine. Will widespread
adoption of AI reduce human contact in medical care? We are at a very early point in the wise adoption
of artificial intelligence. The explosion of AI enabled devices in the home and office will increase the
challenge of assuring protection from malicious hacking as well as insuring personal security and privacy.
The specific performance requirements of a sensor can vary widely depending on the application. A
sensor designed for use in a battery powered consumer device will put a premium on low power
consumption and cost, with less concern about long service life. Sensors designed in medical equipment
will demand reliability, long service life and accuracy. Military and aerospace equipment manufacturers
rate durability and reliability in extremely harsh environments a primary requirement. To some degree
these variations have segmented the sensor market with large suppliers addressing the entire universe
of OEMs while others have chosen to specialize in sensors that are designed to support the unique
characteristics of a single market or even application.
Sensors based on microelectromechanical systems (MEMS) technology offer advantages of size, cost,
low power consumption, as well as the ability to fuse multiple sensors on a single chip. The result of
11 -5
sensor fusion is the ability to extract more useful data, than would be possible using multiple discrete
sensors. Some proposals call for a “universal” multi-sensor module that would contain basic sensors
such as temperature, humidity, vibration, barometric pressure, and perhaps a camera. These modules
could be deployed in a variety of environments that range from a home to a factory floor. Unique
software using advanced algorithms would analyze the inputs to create a software defined sensor that
automatically adapts to the requirements of a specific application. This universal sensor could become a
commodity product, with high production volumes by many vendors that drive the price down. It is yet
to be determined if this is a practical solution to address the many unique applications of the future.
Connector manufacturers that have entered the sensor arena typically maintain a separate sales and
marketing group to support their sensor sales. A connector sales opportunity can be expanded to
include sensors. The much larger group of connector sales people are given basic training that enables
them to identify sensor opportunities which are then turned over to the specialty group to support and
close the sale. Coordination between the two groups can ensure a system level solution benefiting both
the component supplier and customer. OEM buyers like the opportunity to drive contract pricing on
bundled products, from a reduced list of suppliers. Many sensor manufacturers also market their
products through a network of authorized distributors. In many cases, these locally procured sensors
are used to build prototype systems. Purchase of sensors for volume production of the final product
occurs offshore.
Shrinking the size of electronic components has been an ongoing mandate of the industry and includes
the profile of electronic sensors. MEMS sensors offer advantages of reduced size, power requirements
as well as the ability to integrate multiple sensors on a single semiconductor chip. Next-generation
microfabrication tools are now able to assemble structures down to nanometer dimensions. A team
from the Femto-ST in France, using the new μRobotex nanofactory system has demonstrated the ability
to assemble microstructures on the tip of an optical fiber with extreme accuracy. Practical application
of this technology could, for instance, assemble sensing elements on the tip of an optical fiber as thin as
a human hair, which could then be inserted into blood vessels to detect viral molecules.
Nanoelectromechanical sensors, (NEMS) built on an atomic scale will usher in the next generation of
microelectronic devices It may take some time to work out challenges in manufacturing as well as
rethinking what is possible using this unique capability.
The type and extent of commitment that connector manufactures have made to participating in the
electronic sensor market varies considerably. Amphenol and TE Connectivity have been actively adding
to their catalog of sensors through acquisition. Molex has been somewhat selective in testing the
sensor market with a limited line of integrated sensor assemblies and sensor related products. AVX and
Methode have entered the market relatively recently through acquisitions. Samtec participates by
offering their advanced packaging capabilities to manufacturers and users of sensors. Sensata is
primarily a sensor manufacturer that supports nearly every market while offering only one very specific
series of test and burn in connectors.
11 -6

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Report P-770-18 Connector Manufacturers Connect to Sensors is a

1209 Fox Glen Drive

 Report P-770-18 Connector Manufacturers Connect to Sensors (July 2018) NEW

 Report M-700-18 World Connector Market Handbook (March 2018) NEW

 Report F2017-02 Connector Industry Forecast (December 2017)

 Report M-121-17 2017 Top 100 Connector Manufacturers (August 2017)

THE BISHOP REPORT - CONNECTOR INDUSTRY YEARBOOK

Bishop & Associates Inc.

Chapter 1 Report Scope and Methodology

Chapter 2 Executive Summary

Chapter 4 Sensor Types and Technologies

Chapter 5 Sensor Applications

Chapter 6 Sensor Industry Leaders

Robert Bosch GmbH / Bosch Sensortec………………………………………………………………………………………...6-3

Chapter 7 Sensor Industry Standards

Chapter 8 Connector / Sensor Manufacturer Synergy

Chapter 9 Sensor and Application Trends

Chapter 10 Sensor Market Values and Forecasts

Chapter 11 Major Findings and Conclusions

Chapter 1 Report Scope and Methodology

Issues addressed in this report

Methodology and Approach

Our approach to this project included:

▪ Interviews with knowledgeable electronics industry personnel involved in the

▪ Interviews with representatives of applicable industry standards organizations.

▪ Interviews with related market researchers and independent consultants familiar

▪ Collection and review of technical articles and advertising in industry trade

▪ Interviews with leading manufacturers of electronic connectors and sensors.

▪ Extensive Internet searches for related data.

▪ Utilization of the Bishop and Associates database of electronic connectors as well

Chapter 2 Executive Summary

years into the future, but the handwriting is on the wall.

Connector Manufacturer Issues

2. There has been a wholesale transfer of connector manufacturing to offshore locations,

Our eyes are able to convert a narrow band of electro-magnetic

As our world became more advanced, complex

Much like these devices, electronic sensors are the

General Sensor Types and Technologies

1. Binary sensors that detect a specific condition such as fire or water.

The Internet of Things will depend on a host of standard and

Typical cars today contains dozens of sensors that will grow in

Flow rate, temperature, position, and pressure

Chapter 4 Sensor Types and Technologies

Sensors fit into two broad categories

One of the simplest forms of sensing device

A Hall Effect sensor generates an output voltage in

Photocells convert incoming photons to a

Portable heat sensors measure

Air or gas pressure sensors can

Pressure can be measured using

The proximity, direction, and speed of moving objects can be

Location and direction sensors may use

Biometric sensors used in fingerprint

Touch sensors use changes in capacitance as well

Motion sensors detect variations in sonic

Infrared detectors sense changes in heat

Unique properties of a specific material can

A thermocouple uses the thermoelectric effect

Solid state CCD and CMOS based

Non-contact capacitive sensors utilize a

Water quality or turbidity can be

New Zinc sulfide nanoparaticle based chips identify and

MEMS based sensors including accelerometers, gyroscopes, compasses, high-resolution cameras,