December 15, 2023
Harnessing the Power of Flux for Industrial Sensing Applications
Share
BuildWithFlux
Starting a new hardware project can be overwhelming, but the completely overhauled Copilot simplifies the process by guiding you through component selection, spec verification. Just describe your goals and Copilot engages in a focused conversation to refine your requirements like a seasoned hardware engineer.
Ask me a structured set of questions (about 5 one at a time) to help brainstorm and outline the most important parts of a project including the critical technical requirements, including power, components, performance, constraints, Use case etc
Always provide multiple options where applicable, considering trade-offs in cost, efficiency, size, and performance. By the end of this process, I want:
1. A block diagram illustrating the system architecture.
2. A complete list of all components, including passives and active components.
Instead of wading through datasheets and Google searches, use Copilot to select appropriate parts for implementation, recommending main and alternative components that meet design requirements. Tip: You can use tool like @library to direct Copilot to search the part library, or @file to direct Copilot to use datasheet details in it’s responses.
@library List out 5 switching regulators that I can use for my project with a maximum output current of 2A. Include key parameters such as input voltage range, output voltage range, switching frequency, efficiency, and package type.
@file extract the following details from the datasheet of @U2
1. Key features
2. Functional Pin Description
- List each pin with its name, function, and relevant electrical characteristics.
3. From the Typical Application Circuit:
- List all components present along with their values in a table format.
- Describe explicitly how each pin is connected.
4. Any circuit-Specific Design Notes
Identify alternative components for @U4 with similar functionality, pin configurations, and electrical characteristics. Include key differences and trade-offs.
@file extract the absolute maximum ratings of @U1 including voltage, current, and thermal limits. Present the data in a clear table format.
@file Explain @U1 in detail, including its purpose, key functions, and common applications. Describe how it operates within a circuit and any notable characteristics. Also, explain the family or series this component belongs to, highlighting its variations, key differences, and typical use cases compared to other models in the series.
@file Extract the recommended operating conditions for @IC2. Retrieve key parameters such as supply voltage range, operating temperature range, input/output voltage levels, and other relevant conditions specified for optimal performance.
Compare LMR33630ADDAR and MP2451DJ-LF-Z in terms of efficiency, output ripple, load regulation, and thermal performance. Highlight key differences in topology, switching frequency, and suitability for a [specific application, e.g., battery-powered wearable]. Provide a recommendation based on [input voltage range, output voltage, current requirements.
Analyze all the parts in the project context and generate a consolidated parts table that optimizes component selection. Specifically, apply the following consolidation rule:
- Identify passive components (resistors, capacitors, inductors) with the same values but different MPNs (Manufacturer Part Numbers).
- Propose a single standardized MPN for each unique value, prioritizing parts with better availability, and popular supplier.
Present the table clearly. The table must strictly list and analyze all passive components in the project context. It must not use vague terms such as “etc.” or truncate the list in any way. The table should have the following headers (Original Part Category (e.g., Resistor, Capacitor, Inductor), Original Values/Specs (e.g., 10kΩ, 1μF, 100mH), Original MPNs (List all variants found in the project), Proposed Consolidated MPN (Recommended single part), Reason for Consolidation (e.g., same specs, better tolerance, reduced part diversity)
Copilot isn’t just here to answer questions—it can take direct action in your project, helping you place components, modify properties, and refine your design faster than ever. Instead of manually searching for parts or tweaking values one by one, you can ask Copilot to handle specific tasks, like adding a resistor with a defined value or updating a component’s footprint.
When Copilot detects an action it can execute, you’ll see an action button appear—click it to apply the change instantly. If you don’t see a button, try rephrasing your request or breaking it into smaller steps. While Copilot can’t yet generate an entire schematic at once, it’s great at guiding you through the process, handling tedious tasks, and keeping your workflow smooth.
I want the 555 timer to operate at a frequency of 1.5 kHz.
@library add the following components to the project:
- NE555 Timer IC
- 2-Pin Terminal Block Connector (for power input)
- Resistors:
- R1 = 10kΩ
- R2 = 100Ω
- R3 (Current-limiting resistor for output)
- Capacitors:
- C1 = 100nF (0.1µF)
- C2 = 0.1µF (Decoupling capacitor)
- Diode: 1N4148
- LED
- Ground connection
@library add the following components to this project; NE555 Timer IC, 2-Pin Terminal Block Connector (for power input) and two 0603 1k ohm resistors
When working on a design, precise calculations are key—but instead of crunching numbers manually, Copilot can help streamline the process. Whether you need to size a resistor, calculate power consumption, or verify signal integrity, you can use Copilot to gather equations and relevant data before running calculations.
Start by pulling in the necessary formulas and values using @file or @library, ensuring you have all the details upfront. Once you’ve gathered the required inputs, use the @calculator tool to perform the calculations accurately. Taking this structured approach will help you get the most reliable results from Copilot.
@file obtain the equation for sizing the inductor for @U2, along with the required parameter values needed for the calculation.
@calculator calculate the inductor size for U2 needed for my project (Vin = 5V, Vout = 3.3V, Iout = 1A)
@calculator calculate the required PCB trace width for the 12V power rail according to the IPC-2221 standard. The trace should handle a current of 3A with a maximum allowable temperature rise of 10°C. Assume a copper thickness of 1oz and an ambient temperature of 25°C.
@calculator calculate the required decoupling capacitance for @C2 and @C3 considering ±50mv noise/ripple range.
Focuses on early project development to establish a solid project foundation.
@copilot, use mermaid-formatted block diagrams to generate 2 well-detailed architecture design of this project for comparison. Make sure to use the technical and functional requirements information.
@copilot, I’m designing a custom voice-controlled speaker and I initially want it to have buttons, Bluetooth, Wi-Fi, and rechargeable battery. Help me brainstorm and develop a comprehensive product requirements document. Ask me one question at a time, waiting for my response before moving to the next question.
@copilot, validate the the suggested architecture in the block diagram matches the product requirements set for this project. Point out any missing blocks that would be needed to satisfy the requirements.
Brainstorm and optimize modular circuit blocks for faster hardware development.
@copilot, based on my requirements, help me figure out the best power architecture for this project. What should the power tree look like?
Involves choosing appropriate parts for implementation, recommending main and alternative components that meet design requirements.
@copilot, here's the block diagram of this design. In a table format, recommend at least 3 IC for each block highlighting the electrical characteristics of the IC and why you recommended it.
@copilot, list all components specified in the datasheet of U1 for building the typical application circuit. Present the information in a detailed table format with equations needed to size the components.
@copilot, outline the electrical characteristics of U4 as detailed in the datasheet. Then, suggest at least four drop-in replacement parts, presented in a table format with the columns
@copilot, query all components in the schematic that do not have an assigned manufacturer part number (MPN). Compile these components into a table format with the following details: Designator, Component Function, Electrical Properties, and Recommended MPN (Provide a list of recommended part numbers based on the component's properties, focusing on the most popular and widely available parts).
Focuses on optimizing component selection and management, including consolidating similar passive components and addressing part obsolescence to streamline the bill of materials and reduce costs.
@copilot, perform a BoM consolidation review to identify passive components (resistors, capacitors, and inductors) that have similar but different values (within ±50%) and the same package code. The goal is to simplify the BoM and reduce costs by replacing these components with a single value where possible, without affecting the circuit's functionality.
For each group of similar components, compare their electrical and mechanical characteristics, then identify a single value that can replace the others. Provide a detailed comparison table for each group, listing the designators, component values, package codes, and the proposed consolidated value, along with key specifications and any additional notes. Document the final proposed consolidated BoM in a table format.
@copilot, identify all components in the schematic that are either obsolete or not recommended for new designs (NRND). Compile these components into a table with the following details: Designator, Description/Function, Obsolete/NRND Status, Recommended Alternative Parts (Suggest at least 2 alternative components and their MPN that are current, widely available, and suitable replacements, based on the original component's specifications).
Involves precise calculations for sizing various components often using Python for accuracy and presenting results in detailed tables.
@copilot, from the datasheet of U1 obtain equations used to
Calculate these values using python and present the results in a clear and detailed table.
@copilot, use Python to calculate the load capacitors for Y1 using the information from its datasheet.
@copilot, use the datasheets of LED D5 and D2 to obtain electrical characteristics needed to calculate the appropriate current-limiting resistor value. Then use python to calculate the value and present it in a well detailed table forma.
Involves detailed examination of integrated components to ensure proper component selection and usage in the design.
@copilot, from the datasheet of U2 List the pin names, functions, and additional attributes for the IC. Include the following details for each pin in a table format: Pin Name, Function, Pin Type (e.g., power, ground, signal), Pin Direction (e.g., input, output, bidirectional, passive), Default State (e.g., high, low, floating), Voltage Level (if applicable), Additional Notes (e.g., pull-up/pull-down resistor, special considerations).
@copilot What are the absolute maximum ratings for U5? Identify any critical components that must be carefully selected to stay within these limits and present the results in a well detailed table format.
Utilizes Python to create visual representations of design data to assist in analysis and decision-making.
@copilot, use python to plot a bar graph showing the most expensive components in this design.
Provides thorough checks of specific circuit elements to verify correct calculations and implementation in the schematic and layout.
@copilot, list all ICs and the decoupling capacitors attached to each. Ensure to include all ICs present in the design, including digital ICs, power converters, LDOs, etc. For every IC, clearly state:
@copilot, review the design to ensure all current-limiting resistors for LEDs are correctly calculated for a current range of 1mA to 10mA. Follow these steps:
@copilot, determine the efficiency of U4 at various load conditions, considering that the input is a battery with a voltage range from 4.2V (fully charged) to 3.3V (low battery level). Identify which components in the circuit affect this efficiency and present that in a detailed table. Finally, use python to plot a graph showing the efficiency of U1 across the range of load conditions and input voltages.
Generates test plans and collaborative workflows, ensuring your hardware is manufactured error-free.
@copilot, create a detailed step-by-step plan table for this project to verify its functionality.
@copilot, develop an FMEA (Failure Mode and Effects Analysis) report in a table format that analyzes the systems schematic, each unique component specification, and operational parameters. It should identify critical failure modes, assess their impact, and recommend mitigation actions based on severity, occurrence probability, and detectability. Include columns such as: process step, potential failure mode, potential failure effect, S, O, D, RPN, Action Recommended, and any other you see fit.
Copilot can help get you started quickly by understanding the requirements and providing guidance.
@copilot here's a block diagram I've been working on. Can you suggest ICs I might use to implement this in Flux?
@copilot I'd like to build a smart curtain that opens or closes based on the amount of sunshine I want to enter my room. How would you approach designing this? Please ask me questions to help with the development.
@copilot I'm designing a PCB for a medical device that measures heart rate and temperature. Can you give me the list of components I will need?
@copilot I'd like to build geeky wristwatch with LED display. How would you approach building this? Please ask me questions to help me design this.
Copilot can connect complex parts for you, explore design options, and provide a bill of materials for a target project.
@copilot here's a plot of the charging profile of U2. What charging phase would it be in at 3.2V?
@copilot, how would I connect these parts to make the LED flash at 1kHz?
@copilot, how would I connect these two HDMI connectors as a pass through?
@copilot, how should I connect RP2040 and TFT LCD?
@copilot can you choose 4 digital pins on the ATMega328P-AU that I have here to use as GPIO given that I am already using some pins for reset, the external clock, UART, and I2C.
Copilot can understand datasheets and reference them in its responses. This means you get more accurate responses when asking Copilot questions about specific parts.
@copilot what's the max voltage I can supply to U2?
@copilot can U2 withstand intense operating temperatures even without a heatsink?
@copilot what is the maximum frequency I can reach without an external crystal on U6?
@copilot I'm a firmware engineer. How do I configure an interrupt on a pin for U4?
@copilot what are the clock requirements for U4?
Copilot answers questions about how to use Flux by referencing our documentation. So, instead of getting stuck and searching documentation, you can stay in the flow and get the help you need without leaving your project!
@copilot can you explain the different dimensions of this footprint diagram?
@copilot how do I know if a part has a simulation model?
@copilot how do I connect ground to these components?
@copilot I can't find part on the library what do I do?
@copilot how do I know my projects are safe and private?
@copilot what resistor do I need to limit the current on LED1 while being driven by U1?
@copilot can you help me debugging this circuit, and help me understand if there's any problems?
@copilot can you check all my components in my schematic and tell me if I am missing any manufacturer part number fields?
@copilot how would I decrease the distance between my ground fill and my vias?
Copilot can provide valuable recommendations to optimize your design based on constraints and specifications.
@copilot please review this block diagram and compare it to my project, is there anything I'm missing?
@copilot what components do I need to power a 30w speaker to this audio driver amplifier?
@copilot can you suggest a suitable ADC for microphone pickup going through an Arduino Uno?
@copilot can I use U1 to make a 20db gain op-amp?
@copilot I want to build a PCB that uses a solar panel to charge a single cell LiPo battery. I want to measure ambient pressure with a microcontroller and send that over WiFi. What are all the components I would need?
Copilot can offer tailored suggestions and analyze tradeoffs based on your project goals, constraints, and specifications.
@copilot can you suggest an alternative to C1 that meets the same specs but is more cost-effective?
@copilot are there any alternatives to U2 that have better availability?
Flux Copilot has a range of tools to help you through your design process. For the best results, use one tool at a time. This helps Copilot focus on a single task, making its responses more accurate and actionable.
Flux Copilot is here to make hardware design more straightforward and efficient. By following these prompts and tips, you can streamline your workflow, reduce errors, and tackle each step of your project with confidence. Feel free to share your results and favorite prompts in our Slack Community.
Happy designing!
Flux stands out in the PCB design industry, adhering to three core principles: promoting reusability, fostering collaboration, and keeping the designer focused. The emphasis on reusability allows individuals and organizations to amplify their impact. Users can leverage the work of others in the community by using templates, modules, or example projects, saving time and resources. This approach to PCB design not only streamlines the development process but also fosters a collaborative environment where designers can share and build upon each other's work, leading to more innovative and efficient designs. By keeping these principles at the forefront, Flux ensures that designers remain focused on what's most important, allowing them to deliver high-quality, effective PCB solutions for complex industrial sensing applications.
Our PCB design projects, showcased below, are not just innovative solutions but also serve as reusable modules in Flux. Each module is carefully crafted to ensure it can be easily adapted and used by anyone in the community. These modules exemplify the principle of reusability, allowing other designers to leverage our work for their own applications, fostering a collaborative and efficient approach to PCB design.
We developed a high-precision light intensity measurement system using the TSL25911FN. Flux Copilot played a crucial role in optimizing the layout for minimal interference and maximum sensitivity, ensuring accurate light measurement critical in quality control systems within manufacturing processes.
The PCA9615 was the cornerstone of our design for reliable long-distance I²C communication in noisy industrial environments. By leveraging Flux, we successfully mitigated EMI effects, making this design essential for large-scale industrial automation networks.
Utilizing the MLX90640ESF-BAA-000-TU, we crafted a sophisticated thermal imaging sensor. Flux was instrumental in the design, allowing for intricate circuitry that handles the high data throughput and thermal management required for accurate imaging. This sensor has become a game-changer in industrial safety and process monitoring, providing critical thermal data in real-time.
The PGA300ARHHR was the key component in our design of a high-precision pressure sensor system. This sensor is now widely used in fluid dynamics control in various industrial applications, demonstrating its versatility and reliability.
Our design using the VL53L0CXV0DH revolutionized short-range distance measurement in industrial settings. The layout and routing capabilities in Flux allowed us to maximize the sensor's range and accuracy, making it ideal for applications like inventory management and automated guided vehicles.
Incorporating the VL6180X, we developed a versatile multi-range sensor, adept at handling both proximity and ambient light measurement. Thanks to Flux's precision in PCB layout, we achieved a compact design that is now crucial in space-constrained industrial environments, particularly in robotics and assembly lines.
The VL53L1X enabled us to push the boundaries of long-range sensing. This sensor offers exceptional range and accuracy, which is now integral in large-scale automation and monitoring systems.
Our VL53L4CD-based design marked a significant advancement in high-resolution imaging sensors. Leveraging Flux's capabilities, we engineered a PCB that supports complex data processing, essential for applications like precision mapping and 3D modeling in industrial scenarios.
The TMF8801-1BM was central to our innovative time-of-flight sensor design. With Flux, we've enabled us to layout the board more efficiently, resulting in a sensor that excels in real-time positioning and collision avoidance in automated systems.
Using the TMF8820-1AM, we designed a sensor specifically for efficient object detection. The measurement tool in Flux allowed us to create a design that provides high-accuracy detection, making it ideal for safety and surveillance applications in industrial environments.
Our TCS3200D-TR-based design focused on high-fidelity color detection. We achieved a design that offers remarkable color sensing discrimination, essential in quality control processes in industries like textiles and printing.
The ISL29125IROZ-T7 allowed us to develop a high-performance light sensor. This sensor is used extensively in ambient light measurement and color balancing in industrial displays.
In our design with the AFBR-S50LV85D, we specialized in long-range laser measurement. This sensor isideal for applications requiring precise distance measurements, such as in warehouse logistics.
The AR0144CS was the foundation for our high-resolution CMOS sensor. Using Flux, we developed a PCB that supports complex image processing algorithms, crucial for detailed visual inspections in automated manufacturing processes.
Our design using the VCNL3040 redefined proximity sensing in industrial environments. With Flux, we crafted a compact and efficient layout, resulting in a sensor widely used in machinery safety and user interface applications.
The LTR-390UV-01 led to our breakthrough in UV light sensing. Thanks to Flux's layout design tool, we created a sensor that accurately measures UV light intensity, crucial for monitoring and controlling industrial processes involving UV curing and sterilization.
Using the QRE1113, we developed a reflective sensor adept at detecting object presence and positioning. This sensor offers high sensitivity and reliability, essential in applications like conveyor belt control and product sorting in manufacturing lines.
Our design with the GP2Y0D805Z0F focused on compact distance measurement solutions. Thanks to Flux, we were able to create a tiny yet highly effective sensor used in applications where space is at a premium, such as in handheld devices and robotics.
The design journey for each of these modules presented unique challenges, underscoring the versatility and adaptability required in the field of PCB design, particularly when using Flux.
These challenges and others like them were addressed through innovative design approaches, leveraging Flux’s capabilities in layout design and component integration. By overcoming these hurdles, we were able to create modules that are not only effective in their specific applications but also versatile enough to be adapted for a wide range of uses in the industrial sector.
The future of industrial sensing is marked by rapid technological advancements and a shift towards smarter, more efficient systems. Integration of IoT and AI technologies is transforming sensors into intelligent devices capable of real-time data analysis and decision-making. Miniaturization remains a key trend, with sensors getting smaller yet more powerful, catering to space and energy-efficient needs in diverse industrial applications.
Emerging materials and manufacturing techniques promise to enhance sensor sensitivity and durability, crucial for extreme industrial environments. Customization and flexibility in sensor design are increasingly important, enabling quick adaptation to specific industrial needs. This is where tools like Flux, promoting reusability and collaboration, become vital.
Additionally, environmental sustainability and data security are becoming critical considerations in sensor development and deployment. As sensors become more interconnected, ensuring secure and reliable data transmission is paramount.
In conclusion, the industrial sensing landscape is evolving towards more adaptable, intelligent, and sustainable solutions, with immense potential for innovation and impact in various industrial sectors.
We'd love to hear about your experiences with industrial sensor designs or any inquiries you might have. If you're looking for expert advice or services in PCB design, feel free to contact us or join our Slack channel and share with our community of 2,000 and growing. Together, we’ll change the future of PCB design!
Keep Innovating!
Discover how CAD Librarians can leverage Flux’s key capabilities—AI Part Imports, Component Updates, Live Pricing, and JEP30 Export—each tailored to meet the specific demands of maintaining PCB libraries.
With the latest release of Copilot it isn’t just smarter—it’s hands-on, placing components and applying bulk changes to your project instantly. But to get the most out of it, knowing how to craft the right prompt is key.
In this article, we will discuss the key components of the Arduino Uno schematic, including the microcontroller, voltage regulator, USB interface, and passive components, and how they work together to make the board work.
ESP32 microcontrollers are affordable, low-power SoCs with integrated Wi-Fi and Bluetooth. Offering dual-core processing, ample memory, and versatility, they excel in IoT, wearables, and smart home applications. The ESP32's continuous evolution promises exciting possibilities ahead.
Today, we’re taking collaboration one step further by giving hardware teams a shared virtual space that’s built for innovation. Today, we’re launching Flux for Organizations: a new way for hardware teams to collaborate.
Hall effect joysticks use magnetic sensors for precise, durable, and contactless control. They outperform traditional joysticks in gaming, robotics, and industry.
Explore the essentials of schematic diagrams in our comprehensive guide, covering everything from basic resistors to complex integrated circuits, and learn to master the visual language of electronics.
One of the key components of PCBs are vias, which are tiny pathways that allow electrical signals to travel from one layer of the board to another. Vias are a staple of PCB design.
In this post, we’ll explore five common mistakes companies make when contracting PCB design and how you can avoid them by using tools like Flux to keep your project on track, from concept to completion.
Flux Copilot’s new AI-powered part search makes finding and placing components faster and easier using natural language. It eliminates tool-switching and datasheet overload. This streamlines your PCB design workflow.
In this blog post, we explore how Flux.ai effectively uses Web Workers and ImmerJS to enhance data replication in our web-based EDA tool. We discuss our challenges with data transfer, our exploration of SharedArrayBuffer, and our ultimate solution using ImmerJS patches.
This blog will explore functional block diagrams, their pivotal role in system design, the symbiotic relationship with ladder logic, structured text, and the broader realm of PLC programming. Why FBDs are so important within complex systems.
