Artificial intelligence, 5G, and big data technologies are accelerating industrial upgrades across all sectors. With the advent of the Industry 4.0 era, industrial technologies are evolving toward greater intelligence and automation. Industrial automation technology stands as a key focus in China's current industrial development. Millimeter-wave radar sensors, characterized by their strong penetration capabilities, are widely employed in industrial automation projects. The standardized and efficient automated operations of intelligent equipment such as industrial robots and robotic arms are closely tied to the high-precision detection capabilities of millimeter-wave radar.
What Advantages Does Millimeter-Wave Radar Hold Over Other Radars in Industrial Applications?
Currently, radar sensors are primarily categorized into three types: lidar, ultrasonic radar, and millimeter-wave radar. Each type operates on distinct principles and possesses varying detection capabilities. Below, we analyze the advantages of millimeter-wave radar in industrial applications.
Superior Penetration Capability: Based on their distinct operating principles, different radars exhibit varying penetration capabilities. Lidar relies on laser beams to monitor objects and cannot penetrate obstructions. Ultrasonic radar detects objects by emitting ultrasonic waves, which fail to penetrate denser or harder targets. Millimeter-wave radar detects objects by emitting electromagnetic waves, which can penetrate numerous non-metallic materials such as water, glass, and vegetation. Among these three radar types, millimeter-wave radar demonstrates superior penetration capability.
Long Detection Range
LiDAR monitors objects via laser beams, achieving detection distances up to 50 meters when unobstructed. Ultrasonic radar achieves highest detection accuracy between 0.1 and 3 meters, with typical lateral detection ranges up to 8 meters. It is commonly used in automotive radar systems. Millimeter-wave radar operates at frequencies between centimeter waves and microwaves, combining the advantages of both optical and microwave radar for superior penetration. Its typical detection range spans 0 to 200 meters, making it the longest-range option.
It exhibits strong resistance to interference in operating environments. In contrast, LiDAR performance degrades under intense sunlight due to glare interference, affecting detection results. Additionally, high temperatures or smoky conditions can compromise measurement accuracy. Ultrasonic radar relies on ultrasonic waves propagating through a medium. Since the speed of ultrasonic transmission varies with different media, adverse weather conditions like rain, snow, or sandstorms can affect measurement accuracy. Millimeter-wave radar, however, remains unaffected by medium type, light intensity, or temperature, offering strong resistance to external environmental interference.
Millimeter-wave radar outperforms LiDAR and ultrasonic radar through advantages like extended detection range, superior penetration capability, and environmental flexibility. It is now widely adopted in industrial automation. To support this, Texas Instruments has introduced specialized millimeter-wave radar chips for various industrial automation applications.
TI IWR1443 76–81GHz Industrial Security Millimeter-Wave Radar Sensor
As technological capabilities advance, traditional factories are transitioning toward smart manufacturing by integrating automation equipment like robotic arms and intelligent robots. Safety remains paramount in fully automated facilities. To address this, TI has developed industrial millimeter-wave sensors for personnel and object detection. When the sensor detects approaching individuals or objects, it triggers safety systems to minimize collision incidents. Millimeter-wave sensors maintain detection accuracy unaffected by high dust levels or varying light intensity within factory environments.
The IWR1443 is a highly integrated millimeter-wave sensor chip based on FMCW technology. Operating across the 76–81GHz millimeter-wave band, it features shorter wavelengths compared to traditional 24GHz bands. With a continuous bandwidth of 4GHz, it enhances distance resolution, facilitating detection of nearby objects.
The chip integrates a closed-loop PLL ultra-precise linear frequency modulation pulse engine internally. It supports three signal transmission channels and two signal reception channels, with simultaneous operation of two channels during millimeter-wave signal transmission. The IWR1443 comprises two ARM Cortex-R4F radio control systems: one for RF calibration and safety monitoring, the other for chip master control, enabling seamless switching between master and slave dual modes.
For interfacing, it features two SPI interfaces enabling connectivity with peripheral processors for control. Power management employs a low-dropout power network, enhancing power supply rejection ratio. Operating within a wide temperature range of -40°C to 105°C, the IWR1443 utilizes a compact 10.4mm × 10.4mm 161-pin BGA package. This facilitates easier layout design for engineers while minimizing space requirements. Characterized by its small footprint, low power consumption, high accuracy, and wide temperature tolerance, this chip is ideal for industrial applications including factory automation, industrial distance sensors, industrial speed sensors, and safety protection devices.
TI IWR6843 60–64GHz Industrial Smart Robot Millimeter-Wave Radar Sensor
When industrial robots operate alongside humans, they move slowly. Manufacturers of robotic arms and automated industrial robots must enhance environmental sensing capabilities in robot designs to rapidly detect and prevent potential collisions. To address this, TI developed the IWR6843 millimeter-wave radar sensor for robots.
This intelligent sensor chip, based on FMCW technology, performs real-time data processing and decision-making while operating in the 60–64 GHz frequency band. It supports 4-channel reception, 3-channel transmission of millimeter-wave signals, PLL closed-loop control, and hardware acceleration. Its specifications largely align with the IWR1443, differing primarily by integrating a C674x DSP signal processor for enhanced computational power. This radar sensor chip detects objects within 10 meters, with no restrictions on the type of detected target.
Regarding detection angle, it supports a maximum 120° wide-angle detection to accurately sense the surrounding environment, preventing dangerous collisions between industrial robots and other objects or people. The IWR6843 operates effectively in environments with smoke, dust, or poor lighting conditions and can detect transparent objects, meeting industrial production needs and addressing human-machine interaction challenges.
Summary
The rapid advancement of industrial automation is closely intertwined with sensor technology. Millimeter-wave radar stands out for its penetration capability, detection range, and resistance to environmental interference. Compared to lidar, it offers a relatively lower cost advantage and is now widely adopted in industrial production. This technology propels industrial automation forward, positioning it to embrace the era of Industry 4.0 with enhanced capabilities.