Affordable and Hassle-Free Solutions for Obsolete Sensors
Companies that adopted the first microelectromechanical (MEMS) accelerometers and inertial measurement sensors in the 1990s have struggled to find affordable solutions to replace sensors that have been discontinued due to the advent of newer technologies. Although newer sensors feature exponential performance improvements and are available at a drastically reduced cost, they often are not configured to work with existing software, interfaces, or housing. However, with MEMS devices now able to compete with many fiber-optic systems, a new market is on the rise for replacing dated sensors that may or may not be commercially available any more. Inertial Labs offers options to customize sensors so customers don’t need to invest time to make them fit into obsolete sensors and systems.
The History of Inertial Navigation and MEMS Sensors
Initial development with inertial navigation systems began with organizations like M.I.T. Instrumentation Laboratory, Northrup, and Autonetics under sponsorship led by the United States Air Force.
The first accelerometer debuted in the mid-18th century, but it wasn’t until almost a century later that the first gyroscope appeared. After those early devices, it took another two centuries for mechanical evolution to lead to the development of MEMS-based gyroscopes and accelerometers, which we know and use today. In 1993, the first micromachined accelerometer (a MEMS device) hit the market at a mere five dollars per unit. Today, comparable units are available at a fraction of the cost. Moreover, their performance far surpasses the first generation of these sensors.
In theory, that offers end users a great deal more bang for their buck, but the reality is not quite so simple, particularly when trying to retrofit the new sensors into their existing systems.

Replacing Obsolete Sensors Comes at A High Cost
Since the early 1990s, many companies have disregarded or discontinued MEMS-based sensors. On the one hand, it makes sense to stop manufacturing sensors that are no longer considered efficient or sufficiently high-performance, especially compared to the same century’s fiber-optic systems.
However, customers have invested considerable time and resources to integrate these older sensors with their systems and replacing them isn’t always easily done. These companies are often left behind, struggling to find affordable options for the often-costly replacement solutions.
How Obsolete Sensors Are Costing Companies
Replacing existing sensors is not as easy as purchasing and plugging a new sensor into the existing hardware. Companies must consider many other factors as they seek replacement solutions, and they typically are both costly and time-consuming.
Making Custom Modifications to Hardware Interfaces
Retrofitting a new MEMS sensor into an existing hardware interface may require custom modifications to ensure the retrofit connects appropriately. Moreover, since the solution typically needs to be repeated across multiple devices, making it fit isn’t a reasonable option. Instead, companies must engineer a durable fix that is easy to duplicate and install to connect the new sensors to the existing hardware.

Rewriting Software and Firmware to Work with Old Data Packets
Newer MEMS sensors come with software and firmware that deal with the data types the newer systems need to generate. Frequently, the way this new data is generated and sent to the existing device is incompatible with the existing system. As a result, the programs and back-end computations must be rewritten to ensure the system operates correctly.
Developing New Mounting Brackets to House New Components
Just as the hardware interfaces, particularly the plugs and the wiring, must be upgraded, so must the mounting brackets to ensure the new sensors securely fasten inside the housing. These brackets must be designed to securely mount to the carrier object in the existing orientation method, meaning they typically must be custom-designed and manufactured.
Difference in Data Rates and Communication Rates May Change System Performance
Although rewriting the system computation software and firmware for the new sensor will solve problems related to how data is transmitted, problems may remain with the system itself. After all, when a new, high-performance sensor is introduced to an older environment, the other components must work differently to keep up with the higher data and communication speeds. This means that the system must be carefully monitored and tested to ensure that changes in baud and data rates allow the system to function appropriately.
The price of Replacing Discontinued Unit is Unaffordable.
Since these older sensors are discontinued, it is becoming increasingly difficult for companies to locate available discontinued units. As a result, even if they can be located, they come at a higher cost that is usually impractical and out of budget.
A “Done for You” Solution That Eliminates the Hassle
Inertial Labs customers will always be taken care of with the intentional focus directed to the needs presented by customer requirements. One way we take care of ourselves is by offering an option to use our sensors as direct replacements for obsolete or discontinued sensors. We can put our sensors into a form factor compatible with the aging, expensive, or no longer-available products. Inertial Labs wants to reduce R&D and programming time for customers seeking replacement solutions for discontinued sensors. We can help solve the problems they face due to obsolete sensors in four critical ways.
Four Ways Inertial Labs is Helping Customers Replacing Obsolete Sensors
1. Custom Housing for End Users
Instead of worrying about engineering workarounds to mount our sensors within the existing housing, you can be confident that our solution will work. We can create fully customized housing so our sensor units fit well with your existing products.
2. Modify Firmware to Communicate with Existing System
You don’t need to divert your developers and programming personnel from essential tasks to modify software or firmware to work within your existing systems. The teams at Inertial Labs can make critical modifications to sensor firmware such that the programs our sensors communicate with will ensure proper integration.
3. Output Custom Data Packets
Customers whose systems have specific data packet requirements don’t need to worry about reformatting or restructuring their data interpretation protocols. We can configure our units to output custom data packets so that your time is well spent.
4. Configure System with Custom Interfaces
You don’t need to spend valuable time trying to reverse-engineer the interface or our sensors to have a solution that works. We can set up our systems to work with your custom interfaces.
Costly Retrofits are a Thing of the Past
Companies no longer need to invest considerable time or money into R&D just so that their existing products continue to work. We can help ensure that new sensors fit the older housings. We can also provide “done-for-you” hardware and software solutions. You can continue using existing systems with upgraded sensor performance at a significantly reduced cost.
Inertial Labs can help bring replacement units for obsolete sensors made by:


