Inside your product, it is your design
OEM sensor integration means incorporating a sensor into another manufacturer’s product. Mechanical fit, electrical interfaces, configuration, production volumes and long-term supply all affect the design. Gill supports OEMs with configurable wind, level and position sensors, and can adapt existing technology or develop custom sensors where standard products do not meet the requirement.
How do you integrate a sensor into your own product?
A sensor built into your product becomes part of its design, production and support. Mechanical fit, electrical interface, configuration, production volumes and product lifecycle all need defining early, before the enclosure and electronics are fixed. The answer may be a catalogue sensor, a configured version of an existing one or a custom development programme.
A sensor incorporated into a finished product becomes part of its design, production process and service requirements. Its dimensions affect the enclosure, its electrical interface affects the electronics, and its configuration may determine how the product is manufactured and supported.
A standard sensor may meet the measurement requirement but still need changes to its length, mounting, outputs or configuration. Where those adjustments are insufficient, a more extensive engineering solution may be needed.
The earlier these constraints are identified, the easier it is to assess the right approach before the wider product design is fixed.
Key requirements include:
Mechanical integration: available space, mounting, travel, enclosure and the relationship between sensor and mechanism.
Electrical interface: supply voltage, outputs, connectors and compatibility with the host electronics.
Configuration: whether one sensor can support several product variants through software settings.
Production volumes: expected quantities, manufacturing requirements and repeatability between units.
Product lifecycle: supply continuity, revisions, spares and service requirements throughout the product’s life.
Sensor configuration and custom development
OEM requirements do not always need a bespoke sensor. Depending on the application, the solution may be a standard catalogue product, a configured version of an existing sensor or a custom development programme.
Configurable sensors
Software configuration can allow an existing sensor to support different applications or product variants without requiring a new hardware design for each one. Gill’s Blade position sensors, for example, can be configured using BladeCom software.
Application-specific mechanical design
Some applications require a sensor to fit a particular mechanism, tank or installation. Blade position sensors use an activator as part of the customer’s mechanism, with standard activator designs available as a starting point. Gill level sensors can be developed to suit specific tank lengths and shapes.
Custom sensor development
Where an existing product or configuration cannot meet the requirement, Gill engineering can adapt existing technology or develop a sensor for the application. The scope depends on the measurement, mechanical, electrical and environmental requirements.
Comparing OEM development options
The best route depends on how closely the application matches an existing product and what needs to change.
| Consideration | Catalogue sensor | Configured sensor | Custom development |
|---|---|---|---|
| What changes | No product changes | Settings, outputs, lengths or mounting, where supported | Mechanical design, electronics or firmware as required |
| Development effort | Lowest | Limited to configuration and integration | Greater engineering and validation effort |
| Lead time | Typically shortest, subject to availability | Depends on configuration and availability | Requires an agreed development programme |
| Gill examples | WindSonic, MaxiMet | Blade position sensors configured through BladeCom; level sensors made to length where available | Custom level sensors and LevelDefend builds |
| Best suited to | Applications that meet catalogue specifications | Series products with requirements supported by an existing platform | Applications that cannot be met by standard or configurable products |
A configured sensor is often the most straightforward starting point when it meets the application requirements. Custom development becomes relevant when the mechanical, electrical, measurement or environmental constraints cannot be addressed through an existing product.
Design and production considerations
Development time
Custom development requires requirements definition, engineering, prototypes and validation. The time required depends on the complexity of the design and the testing needed. Configuration or catalogue integration may offer a shorter route where the existing product meets the specification.
Integration and support
Standard products can simplify sourcing and servicing. Configured and custom sensors may introduce additional requirements for documentation, production control, replacement units and technical support.
Electrical and mechanical interfaces
Connector, output and mounting choices affect the wider product design. Confirm these requirements early to reduce the risk of changes to both the sensor and the host product later in development.
Product lifecycle and change control
Agree how product revisions, component changes, availability and spares will be managed. These considerations are particularly important when the sensor is embedded in equipment expected to remain in production or service for many years.
Gill sensors for OEM applications
Gill’s sensor technologies are used in OEM applications where wind, position or liquid level measurements need to be incorporated into another product. The appropriate range depends on the measurement, integration constraints and required performance.
Wind measurement: WindSonic
WindSonic is a two-axis ultrasonic anemometer suited to OEM applications requiring wind speed and direction measurement. Its configurable output options allow integration with different host systems, subject to the selected model and interface.
Position measurement: Blade sensors
Blade position sensors provide non-contact position measurement and can be configured using BladeCom. Standard activator designs provide a starting point for integration with the customer’s mechanism.
Liquid level measurement: custom level sensors
Gill capacitive level sensors can be developed for the liquid, tank geometry and integration requirements of an OEM product. The design needs to account for the application and the required sensor dimensions and interface.
insight
Configuration, integration and engineering
OEM sensor selection is only part of the design process. The sensor must also work with the host product’s electronics, mechanics, software and service requirements.
Blade position sensors illustrate this approach. BladeCom supports sensor configuration, while the activator forms part of the customer’s mechanism. Integration therefore involves both the sensor settings and the mechanical arrangement. The Blade developer guide provides further information for OEM design work.
Where standard products or supported configurations cannot meet the requirements, Gill’s engineering and R&D capability can be considered for a more tailored solution. The feasibility, development scope and validation requirements need to be agreed for each application.
Related technical resources
CapabilityEngineering and innovation
Information about Gill’s engineering and R&D capability.
ManualBlade sensors developer guide
Integration guidance for OEM position sensing.
SoftwareBladeCom configuration software
Software for configuring Blade position sensors.
KnowledgeFuel level sensing for UAVs
Technical information on fuel-level sensing for weight-critical platforms.
Speak to our team
Tell us what you need to measure, where and under what conditions. We’ll help you work out the appropriate approach.
Frequently asked questions: OEM and custom sensors
OEM sensor integration is the incorporation of a sensor into another manufacturer’s product or system. It involves more than selecting the correct measurement technology: mechanical fit, electrical interfaces, configuration, production requirements and long-term support all need to be considered.
Gill can adapt existing technologies or develop custom sensors where a standard product or supported configuration does not meet the application requirements. The feasibility, engineering scope, development time and validation requirements depend on the measurement and integration constraints.
Gill sensor options for OEM integration include WindSonic ultrasonic anemometers for wind speed and direction, Blade position sensors for non-contact position measurement, and capacitive level sensors that can be developed for specific tank and installation requirements. The right choice depends on the application and required interfaces.
Gill Blade position sensors can be configured using BladeCom software. The activator is part of the customer’s mechanism, with standard activator designs available as a starting point. OEMs should review the Blade developer guide and confirm that the sensor configuration and mechanical arrangement suit their design.
A useful initial specification includes the measurement required, operating environment, available space, mounting and mechanical constraints, electrical interface, expected production volumes and target timescale. Details of the host product and any relevant validation or lifecycle requirements will also help establish the appropriate development route.
No. A catalogue sensor or configured product is usually the simpler route when it meets the application’s requirements. Custom development is worth considering when standard products cannot satisfy the necessary measurement, mechanical, electrical or environmental constraints.
There is no single lead time for custom sensor development. It depends on the complexity of the requirements, the engineering work involved, prototype iterations and validation. Gill would need to review the application before providing a realistic programme.
Potentially. Where the sensor supports software configuration, one hardware platform may be suitable for multiple product variants. The available settings, interfaces and limits depend on the specific sensor. Confirm the required configurations with Gill before designing the production process around a shared part.