Technical overview of MicroWire sensing system
MicroWire technology enables passive, contactless measurements across diverse industries. Ultra-thin metallic wires coated in glass are both small and highly sensitive, allowing precise measurement of various physical parameters.
Functional Architecture
Our sensing solution consists of 4 important parts: the MicroWire sensor, sensing coils, MCU and custom software. The sensor detects magnetic changes, the coils capture responses, and the MCU processes and transmits data wirelessly.
1. MicroWire Sensor
MicroWire provides an exceptional combination of properties, such as micro-dimensions, passive character, the ability to be incorporated inside the materials and contactless sensing.
MicroWire sensors are ultra-thin, magnetic sensors with diameters ranging from approximately 3 to 70 micrometers. Each sensor consists of a metallic core (typically 1–50 micrometers) surrounded by a protective glass coating (2–20 micrometers). This unique structure provides the sensor with both durability and high sensitivity to magnetic fields.
The passive nature of MicroWire sensors means they do not require an internal power source. Instead, they rely on external magnetic fields to generate signals, allowing them to operate continuously with minimal energy consumption. This feature makes them ideal for applications requiring long-term, maintenance-free monitoring.
2. Sensing System
Sensing the information from the MicroWire can be performed from a distance of up to 10 cm through the materials: metallic and magnetic ones; employing an excitation and sensing coil.
The sensing system utilizes excitation coils to generate an alternating magnetic field around the MicroWire sensor. The sensing coils then detect the sensor's magnetic response, which varies depending on the surrounding physical conditions, such as temperature, pressure, or deformation. The shape of the coils can be adapted to the environment, ensuring optimal performance in diverse applications.
Excitation and sensing coils do not need to be part of the same device or enclosed in a single housing. They are able to withstand temperatures up to 200°C and can be protected with specialized shielding for even greater durability in extreme conditions.
The captured signal is filtered, amplified, and converted into digital data for analysis. This contactless sensing method ensures that measurements can be taken without physically touching or altering the monitored object, making it perfect for use in harsh or delicate environments.
Microcontroller (MCU)
Sensing system is wired to distant electronics containing an ARM chip, which digitizes the obtained signal. Data is sent via cable or wirelessly to be processed, saved, and evaluated.
The processed signals from the sensing coils are transmitted to a microcontroller unit (MCU), which handles data processing and communication. The MCU is equipped with advanced algorithms to filter noise, amplify the desired signals, and convert them into meaningful data.
To ensure seamless integration into modern systems, the MCU supports various connectivity options, including USB, Bluetooth, SigFox and Wi-Fi. This flexibility allows data to be transmitted in real-time to monitoring systems, enabling remote diagnostics and instant analysis.
4.Software
The custom software processes raw data from the sensing system, enabling detailed calibration, visualization, and analysis tailored to specific applications.
Custom-developed software is designed to work with MicroWire sensors and the MCU, providing efficient tools for data management and analysis. The software enables signal calibration, real-time monitoring, and post-processing of the digitized data. Users can adjust parameters and settings to optimize measurements for their specific operational needs.
This software is capable of processing data from multiple sensors simultaneously and provides tools for integration into existing analytical or monitoring platforms. Its functionality ensures precise handling and interpretation of measurement data, supporting accurate diagnostics and tailored applications across various industries.
Dive deeper
into technical specifications
MicroWire sensors leverage their unique magnetic properties to perform both direct and indirect measurements, enabling precise monitoring of various physical parameters using a bistable MicroWire material.
Measurement principles
MicroWire sensors leverage their unique magnetic properties to perform both direct and indirect measurements, enabling precise monitoring of various physical parameters using a bistable Microwire material.
Direct Measurements
Parameters such as temperature, stress, and magnetic field strength are measured directly by MicroWire sensors.
MicroWire sensors directly measure parameters such as temperature, stress, and magnetic field strength. These measurements are unaffected by magnetic noise, despite the sensor's magnetic nature. Unlike conventional magnetic sensors that rely on high permeability and high saturation fields, RVmagnetics sensors operate with permeability close to vacuum (~1) and a low saturation field (~3 Oe). This enables precise temperature readings across a wide range and accurate stress detection without interference.
Additionally, pressure measurement is uniquely linear across its entire range, remaining unaffected by temperature variations, and vice versa - temperature readings are entirely independent of pressure changes.
Indirect Measurements
By analyzing their magnetic response, MicroWire sensors accurately determine additional physical parameters beyond direct measurements.
In addition to direct measurements, MicroWire sensors can infer other physical parameters based on their magnetic response, such as bending, torque, strain, flow, vibration and others. The sensors detect shifts in the magnetic field caused by these factors, allowing them to provide non-contact monitoring of material deformation or structural changes.
Embedding & Signal Processings
The MicroWire can be seamlessly embedded within various materials without creating defects. Unlike conventional sensors that output voltage, these sensors convert measurements into time-based data reflecting the velocity of domain wall propagation. This time-based data is then processed using high-resolution counters in ARM chips or FPGA systems, leading to significantly enhanced measurement accuracy and precision.
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MicroWire under Microscope
Under microscopic examination, MicroWire sensors exhibit a distinctive structure comprising a metallic core encased in a glass coating. his glass-coated design not only provides durability but also enables integration of the MicroWire into various materials without compromising their structural integrity.
The unique combination of a metallic core and glass coating results in specific magnetic properties, allowing the MicroWire to function as a passive sensor. This design facilitates contactless sensing of physical quantities such as temperature, pressure, and magnetic fields, even when embedded within materials like metal, composites, concrete, wood, or human tissue.
Crafted with Precision
Glass-coated MicroWires are composite materials consisting of a metallic core covered by a glass layer. These are produced by drawing and rapidly quenching molten alloys, resulting in unique properties for both magnetization and mechanical performance.
The unique magnetic characteristics of MicroWires are shaped by magnetoelastic interactions between magnetic moments and mechanical stresses induced during production. These stresses are crucial in determining the sensor’s sensitivity and performance.