Mechatronics System Design

Sensors Selection
Dr. Ashraf Saleem

Displacement Sensors Selection Procedure (1/8)

The f ll i Th following steps are general steps f choosing a di l l for h i displacement sensor for a particular application: The first parameter to address in any application is whether the p y pp transducer can physically touch the object being monitored. If your application is sensitive to outside influences, a noncontact transducer may be the most appropriate. Otherwise, a contact appropriate Otherwise sensor might offer advantages not found in a noncontact sensor. Another parameter to consider early is whether you need to measure li linear or rotary movement. Using cable position t t U i bl iti transducers, cams, pulleys, levers, electronics, software, and other methods can enable a rotary transducer to measure linear motion, and vice versa. Lack of space, cost, and ease of mounting are a few reasons for doing this.

Dr. Ashraf Saleem/ Philadelphia University

Displacement Sensors Selection Procedure (2/8)

Next, determine if you are monitoring one-dimensional or multidimensional motion. If the motion is multidimensional, decide if you need t measure i multiple di d to in lti l dimensions or if th object i i the bj t is moving in multiple dimensions and you only have to measure one of them. Often, multidimensional motion is measured with multiple onedimensional transducers. Also, think about the type of signal you need to obtain. If you need a signal that specifies a unique position be sure to specify a position, transducer with absolute output. However, if all you need is relative position from a prior position or a simple on/off indicator, then incremental or threshold technology is more appropriate appropriate.

Dr. Ashraf Saleem/ Philadelphia University

Displacement Sensors Selection Procedure (3/8)

The range of many precision transducers is limited to 10 inches or less. If your application needs to operate on the International Space Station St ti or some other size- and weight-sensitive platform, you need th i d i ht iti l tf d to specify the maximum values for the dimensions and weight of your transducer. The operating environment of the application can have a large impact on your technology choice as well. You need to determine what operating and storage temperatures the device will be in and whether you need to meet commercial, industrial, or military environmental requirements. Also consider whether excessive humidity, moisture shock, vibration, humidity moisture, shock vibration or EMF will be encountered encountered. See if your environment has other unique aspects, such as high or low pressure or the presence of hazardous or corrosive chemicals.
Dr. Ashraf Saleem/ Philadelphia University

Displacement Sensors Selection Procedure (4/8)

An often-overlooked parameter is the method and time required for p q transducer installation and mounting. For testing applications, this parameter may not be so important. However, large-volume applications often require simple installation and removal to reduce labor costs and enable easy maintenance. Study the device accuracy. Typically, various components of accuracy - linearity repeatability resolution, and hysteresis - are linearity, repeatability, resolution quoted for vendor convenience or per user requirements. In the early stages of transducer specification, product cost sometimes does not even make the list. More often than not, this parameter gains importance as the project moves forward. When y you are determining costs, make sure to look at the initial acquisition g , q cost as well as the cost over the life of the product. For example, are special signal-conditioning electronics, power supplies, electrical connectors, housings, connectors housings installation tools or mounting fixtures tools, required?
Dr. Ashraf Saleem/ Philadelphia University

Displacement Sensors Selection Procedure (5/8)

Another parameter that is occasionally overlooked is the time it p y takes the product to be delivered to you after you order it. The custom nature of some transducers, combined with production processes and manufacturing economics, requires lead times of eight weeks or more. This delivery schedule might be acceptable now, but six months from now you may need extra quantities or a spare part Evaluate whether you can afford to be without a part for part. an extended period of time. Obviously, the transducer is going to be a part of a system. Therefore, determine your preferred electrical input and output f f requirements. Common output choices include analog AC and DC voltage, resistive, current (4-20 mA), digital, and visual (meter). Increasingly, outputs using sensor bus protocols are being offered. Most position transducers require 50 V or less, and some are selfp powered.
Dr. Ashraf Saleem/ Philadelphia University

Displacement Sensors Selection Procedure (6/8)

Finally, for fast-moving applications, determine the maximum y g pp velocity or acceleration that needs to be monitored. Ensure that your data-acquisition or control system has an adequate sampling rate to record the resulting data stream.

Dr. Ashraf Saleem/ Philadelphia University

Displacement Sensors Selection Procedure (7/8)

Parameter Contact Motion Type Dimensions Measurement Type Range Physical Size/Weight Contact Linear One Dimensional Absolute Less than 1" Incremental 1"-30" Choice Non-contact Rotary Multidimensional Threshold (Proximity) Greater than 30" Weight Restriction ______ Temper ature

Size Restriction _______

Environmental Protection

Humidity

Vibration

Moisture Installation Time _____ Repeatability

Installation/Mounting Accuracy

Removable Linearity

Fixed Resolution

Lifetime

Cycles _______

Hours of continues operation _______

Cost Delivery

Less than $50 Less than 1 week

$50-$500 14 1-4 weeks Digit al

More than $500 More than 4 weeks

Output

Voltage

Current

Visual

Frequency Response

Less than 5 Hz

5-50 Hz

More than 50 Hz

Dr. Ashraf Saleem/ Philadelphia University

Displacement Sensors Selection Procedure (8/8)

Dr. Ashraf Saleem/ Philadelphia University

Temperature Sensors Selection Procedure

Temperature Limitations for RTDs
An RTD consists of a sensing element, wires to connect the sensing element to the measurement instrument and some kind of support to position the sensing element in the process Each of these materials process. sets limits on the temperature that the RTD can be exposed to.

Dr. Ashraf Saleem/ Philadelphia University

Temperature Sensors Selection Procedure

Temperature Limitations for RTDs
The wires which connect the sensing element to the readout or control instrumentation are usually made of materials such as nickel, nickel alloys, tined copper, silver plated copper or nickel plated copper. The wire insulation used also directly influences the temperature the RTD can be exposed to Table 2 contains the commonly used wire and to. insulation materials and their maximum usage temperatures.

Dr. Ashraf Saleem/ Philadelphia University

Temperature Sensors Selection Procedure

Temperature Limitations for Thermocouples

Thermocouple materials are available in Types E, J, K, N, T, R, S and B.

Dr. Ashraf Saleem/ Philadelphia University

Thermocouple Applications Th l A li ti

Dr. Ashraf Saleem/ Philadelphia University

RTD Strengths
RTDs are commonly used in applications where repeatability and accuracy are important considerations. Properly constructed y p p y Platinum RTDs have very repeatable resistance vs. temperature characteristics over time. If a process will be run at a specific temperature the specific temperature, resistance of the RTD at that temperature can be determined in the laboratory and it will not vary significantly over time. RTDs also allow for easier interchangeability since their original variation is much lower than that of thermocouples. For example, a Type K thermocouple used at 400F has a standard limit of error of 4F. A 100 Ohm platinum RTD has an interchangeability of 2.2F at this same temperature. RTD s RTDs also can be used with standard instrumentation cable for connection to display or control equipment where thermocouples must have matching thermocouple wire to obtain an accurate measurement. measurement
Dr. Ashraf Saleem/ Philadelphia University

RTD Weaknesses
In the same configuration you can expect to pay from 4 to 10 times configuration, more for an RTD than for a base metal thermocouple. RTDs are more expensive than thermocouples because there is more construction required t make th RTD i l di manufacture of th t ti i d to k the including f t f the sensing element, the hooking up of extension wires and assembly of the sensor. RTDs do not do as well as thermocouples in high vibration and mechanical shock environments due to the construction of the sensing element element. RTDs are also limited in temperature to approximately 1200F where thermocouples can be used as high as 3100F

Dr. Ashraf Saleem/ Philadelphia University

Thermocouple Strengths
Thermocouples can b used to temperatures as hi h as 3100F Th l be d high 3100F, generally cost less than RTDs and they can be made smaller in size (down to approximately .020 dia) to allow for faster response to temperature. Thermocouples are also more robust than RTDs and can therefore be used in high vibration and shock applications applications.

Dr. Ashraf Saleem/ Philadelphia University

Thermocouple Weaknesses
Thermocouples are less stable than RTD when exposed to Th l l bl h RTDs h d moderate or high temperature conditions. In critical applications, thermocouples should be removed and tested pp , p under controlled conditions in order to verify performance. Thermocouple extension wire must be used in hooking up thermocouple sensors to thermocouple instrument or control equipment. Use of instrumentation wire (plated copper) will result in errors when ambient temperatures change.

Dr. Ashraf Saleem/ Philadelphia University