Custom Electronics Development for Sensor Technology

In modern measurement technology, the quality of the electronics is a decisive factor for the precision, immunity to interference, and dynamics of the overall system. Octogon offers specialized hardware and software development for sensor technologies – tailored to your mechanical and metrological requirements.

Whether it's extremely compact inline amplifiers for direct integration into sensor housings, robust DIN rail modules for control cabinet construction, or redundant evaluation electronics for safety-critical applications: we support you from the initial circuit idea to series-ready assemblies.

Our Core Competencies in Sensor Electronics

1. Precise Analog Signal Conditioning & Strain Gauge Evaluation

Strain gauges (DMS), piezo sensors, and capacitive transducers primarily deliver very small useful signals in the millivolt range. Our circuit designs guarantee lossless and low-noise conditioning:

• High-resolution AD conversion: Use of 24-bit Sigma-Delta converters for maximum signal resolution and dynamics.

• Temperature compensation: Hardware and software-based correction of thermal drift effects directly at the sensor.

• Filtering & Immunity to Interference: Active and passive filter stages for effective suppression of EMC interference, ground loops, and high-frequency disturbances.

2. Embedded Electronics & Extreme Miniaturization

Installation space in force measuring bolts, load cells, or torque sensors is extremely limited. We develop highly integrated SMD layouts that fit precisely into the existing geometry:

• In-sensor integration: Complete integration of amplifier, microcontroller, and fieldbus interface in the smallest possible space.

• Robust designs: Layouts optimized for use under harsh conditions (vibration, shock, humidity) including preparation for potting compound and hermetic welding.

• Remote electronics: Development of compact intermediate amplifiers (cable amplifiers/inline modules) for situations where high temperatures or extremely limited space prevail at the measuring point.

Interfaces & Communication

We seamlessly connect your sensor technology with higher-level controls (PLCs), data loggers, or cloud systems:

Functional Safety (Safety by Design)

In crane and lifting technology, automation, and mechanical engineering, strict guidelines apply to functional safety. Octogon develops electronic components according to international standards (e.g., EN 61508, ISO 13849, EN 62061):

• Redundant Architectures: Multi-channel evaluation systems (e.g., 1oo2 or 2oo2 evaluation) to achieve SIL 2 / SIL 3 as well as PL d / PL e.

• Self-diagnosis & Signal Monitoring: Integrated functions for monitoring cable breaks, short circuits, supply voltage, and plausibility of measurement signals.

• Safety Firmware: Development of structured, extensively tested firmware for safety-related microcontrollers.

Our Development Process: From Idea to Series Production

1. Requirements Analysis & Specification: Joint definition of installation spaces, signal type, accuracy classes, protection types, and EMC requirements.

2. Circuit Design & PCB Layout: Creation of circuit diagrams and optimized multilayer PCB layouts taking into account EMC guidelines (EMC-by-Design).

3. Firmware & Software Development: Programming of efficient, robust software for embedded systems including signal filtering and bus communication.

4. Prototype Construction & Qualification: Production of initial samples, performance of EMC pre-compliance tests, temperature runs, and functional tests.

5. Series Production & Final Testing: Manufacturing of electronic assemblies including automated functional testing and individual calibration.

Your Advantage with Octogon: You receive sensor technology and electronics development from a single source. We speak both the language of mechanics and that of digital signal processing – for uncompromisingly reliable measurement systems.

Do you have a specific development project or are you looking for custom OEM electronics?

Talk to our engineers – we develop the right electronics for your sensor task.