Module: 7

Sensor Technology

• Process of developing sensors

• Trends in sensor technology and IC sensors
• Sensor array’s and multi-sensor systems
• Smart sensors
• Industrial network and automation
 Sensor Technology
Sensor Technology

• The formal study of sensor technology is plagued by ambiguity in

definitions and terminology.

• This evolving field of endeavor is extraordinarily broad with nearly every

scientific and technical discipline playing an important role. Thus, it should
not be surprising that there is no unanimous concept of a sensor.

• New Sensor Technologies: Materials and Applications was asked to

identify novel sensor materials that could benefit the manufacture and
operation of advanced systems for the Department of Defense and the
National Aeronautics and Space Administration and to identify research
and development (R&D) efforts that could accelerate the development and
incorporation of these emerging sensor materials in particular applications
with potentially high payoff.
 Sensor Technology

• To provide a foundation for its recommendations in these areas,

the committee began by assessing the current status of sensor
technologies.

• Early in this assessment, the committee found that applications,

not materials, drive new sensor development.

• Therefore the committee identified a conceptual framework that

could relate sensor materials to application needs within which
the importance of particular sensor materials could be
determined.
 Sensor Technology

Fundamentals of sensor technology, considerable ambiguity exists in

sensor definition and classification, as illustrated by both
Physical phenomena
• Acoustic
• Electrochemical
• Hall effect and
• Infrared sensors
Material types such as
• Bimetallic,
• Fiberoptic,
• Thick-and thin-film, and
• Zirconium oxide sensors
Process of developing sensors
 Process of developing sensors
Process of developing sensors

The basic requirement for developing smart sensor is that it be a system with
dedicated "on-chip" signal processing. Realization of this concept simply means
that electronic (or optical) signal processing hardware is dedicated to each sensor
and miniaturized to the point that it becomes a part of the sensor package.
Opportunities for introducing new materials in sensors thus arise from three areas:
(1)Sensor transducer mediums (material);
(2)Sensor packaging materials and
(3)Electronic (signal processing) devices and readouts.

Technological components in current sensor systems include:

(1) Sensor element(s) and transduction material(s);
(2) Interconnection between sensor elements (electrical and/or mechanical)
input "gate";
 Process of developing sensors
Process of developing sensors

• Concurrent synthesis and reliable deposition of high performance

materials require development of sensors to monitor changes in
critical process variables.

• Considers sensor technologies that play a critical role in the

establishment of advanced process control architectures and the
production of quality products.

• There are a wide range of sensor application needs to control the

operation of unit processes monitor and diagnose equipment
condition and to inspect and measure the product. Unit processes of
The future are
Process of developing sensors
Process of developing sensors

Anatomy of a sensor system

 Process of developing sensors
Process of developing sensors

Technological components in current sensor systems include:

• Sensor element(s) and transduction material(s);

• Interconnection between sensor elements input "gate";
• Output "gate" and interconnection;
• Packaging;
• Modulating input interconnects;
• Calibration device;
• Calibration input/outputs;
• Output signal modifying device (amplifier);
• Output signal processing (for smart sensors); and
• Actuators for calibration
 Process of developing sensors
Process of developing sensors
Developing framework:

1. Setting up the performance goals and evaluation criteria

2. Data analysis (exploratory)

3. Data preparation and pre-processing

4. Training and validating the predictive model

5. Testing
Trends in sensor technology and IC
sensors
 Trends in sensor technology and IC sensors
Trends in sensor technology and IC sensors

Following a review of recent developments in sensors and sensing materials, the

committee made several observations that provide the basis for suggesting a
strategy for sensors, in particular for identifying development opportunities in
sensing materials.

• Current sensor development is trending toward increased technical complexity

in sensor systems.
• The principal technical drivers for sensor development may come from
enabling/supporting technologies other than materials technology.
• It is sometimes possible to advance the state of the art in sensing technology by
leveraging materials developed for non-sensing applications.
• Experience in establishing centers of excellence for sensor development
provides useful guidelines for the development of a revised sensor R&D
strategy.
 Trends in sensor technology and IC sensors
Trends in sensor technology and IC sensors

Four common characteristics can be identified in the sensors conducted at

several major centers for sensor technology:

1. A multidisciplinary approach is adopted, with emphasis on teamwork. Those

centers located at universities also expose students to a multidisciplinary
environment which enhances their educational experience.

2. Capabilities exist to develop sensors from an initial research concept through

engineering prototypes to fielded systems (vertical integration). Laboratories
possessing such a broad research base can readily address the root cause of
problems and issues that arise during development. They would be limited in
effectiveness if they participated in only a portion of the development process.
 Trends in sensor technology and IC sensors
Trends in sensor technology and IC sensors

3. Efforts are focused on selected sensor technologies for a broadly defined

range of applications in line with the core competencies of the organization. No
attempt is made to cover the entire field of sensor technology and the associated
diversity of sensor materials. These organizations have access to expertise from
the many technical disciplines involved in sensor technology.

4. Strong linkage to industry is actively encouraged and pursued. Contact with

industrial and end users aids these institutions in insuring the general relevance
of their research areas. Since industry's needs oftentimes tend to be very specific
and narrowly defined, these centers specialize in transferring general knowledge
that can subsequently be applied to solve specific problems.
Smart sensors
 Smart Sensors

One of the most important advances in sensor technology in the last ten years has
been the focused development of smart sensors. The definition of "smart" and
"intelligent" sensing can be debated. In general, it is difficult to identify any features
in a smart sensor that parallel intelligence in natural systems; however, the terms
have become cemented in the technical jargon.

• The basic tenet of smart sensors is that the sensor complexities must be concealed
internally and must be transparent to the host system.
• Smart sensors are designed to present a simple face to the host structure via a
digital interface, such that the complexity is borne by the sensor and not by the
central signal processing system.
• This report does not address specific technologies associated with smart sensing
but instead presents the concept and identifies where and why opportunities exist
for new sensor materials as well as for the utilization of existing materials that
have not traditionally been used for sensing applications.
 Smart Sensors
Schematic representation of a Smart sensor
 Smart Sensors
Subsystems of a smart sensor

The subsystems of a smart sensor include:

• A primary sensing element;

• Excitation control;
• Amplification (possibly variable gain);
• Analog filtering;
• Data conversion;
• Compensation;
• Digital information processing;
• Digital communications processing; and
• Power supply.
 Smart Sensors
Smart sensor
• The principal catalyst for the growth of smart-sensing technology has been the
development of microelectronics at reduced cost.
• On-chip actuators for self-calibration and mechanical compensation may be
created using micromachining techniques or thin-film technologies.
• Many silicon manufacturing techniques are now being used to make not only
sensor elements but also multilayered sensors and sensor arrays that are able to
provide internal compensation and increase reliability.
• It is difficult to predict the future in smart sensing, as the new applications will
be driven by the availability of new sensing materials, an improved
understanding of the transduction characteristics of "old" materials, and
manufacturing techniques for microactuators, microsensors, and
microelectronics. It is clear, however, that the smart-sensing concept creates new
opportunities for using novel materials for sensors.
• The smart-sensing concept makes it possible to avoid the constraint of the
paradigm
 Smart Sensors
Smart sensor
• The principal catalyst for the growth of smart-sensing technology has been the
development of microelectronics at reduced cost. On-chip actuators for self-calibration
and mechanical compensation may be created using micromachining techniques or thin-
film technologies.
• Many silicon manufacturing techniques are now being used to make not only sensor
elements but also multilayered sensors and sensor arrays that are able to provide internal
compensation and increase reliability.
• It is difficult to predict the future in smart sensing, as the new applications will be driven
by the availability of new sensing materials, an improved understanding of the
transduction characteristics of "old" materials, and manufacturing techniques for
microactuators, microsensors, and microelectronics.
• It is clear, however, that the smart-sensing concept creates new opportunities for using
novel materials for sensors. The smart-sensing concept makes it possible to avoid the
constraint of the paradigm that sensor elements must be linear and noise-free; however the
cost of the added electronics must be considered in the sensor system design analysis.
 Smart Sensors
Smart sensor
Potential advantages of the smart-sensor concept include:

• Lower maintenance;
• Reduced down time;
• Higher reliability;
• Fault tolerant systems;
• Adaptability for self-calibration and compensation;
• Lower cost;
• Lower weight;
• Fewer interconnections between multiple sensors and control systems; and
• Less complex system architecture.
Sensor array’s and multi-sensor
systems
 Sensor array’s and multi-sensor systems
Sensor array’s and multi-sensor systems

• A sensor array is a group of sensors, usually deployed in a certain geometry

pattern, used for collecting and processing electromagnetic or acoustic signals.

• The advantage of using a sensor array over using a single sensor lies in the fact
that an array adds new dimensions to the observation, helping to estimate more
parameters and improve the estimation performance.

• For example an array of radio antenna elements used for beamforming can
increase antenna gain in the direction of the signal while decreasing the gain in
other directions, i.e., increasing signal-to-noise ratio (SNR) by amplifying the
signal coherently.
 Sensor array’s and multi-sensor systems
Sensor array’s and multi-sensor systems

• Another example of sensor array application is to estimate the direction of

arrival of impinging electromagnetic waves. The related processing method is
called array signal processing.

• A third examples includes chemical sensor arrays, which utilize multiple chemical
sensors for fingerprint detection in complex mixtures or sensing environments.
Application examples of array signal processing include radar/sonar, wireless
communications, seismology, machine condition monitoring, astronomical
observations fault diagnosis, etc.

• Using array signal processing, the temporal and spatial properties (or parameters)
of the impinging signals interfered by noise and hidden in the data collected by the
sensor array can be estimated and revealed. This is known as parameter estimation.
Sensor array’s and multi-sensor systems
Sensor array’s and multi-sensor systems
Sensor array’s and multi-sensor systems
Sensor array’s and multi-sensor systems
Sensor array’s and multi-sensor systems
Block Diagram of multiple Sensor array’s System
Industrial network and automation
 Industrial network and automation
What is Industrial Automation?

What is Industrial Automation?

Automation takes a step further mechanization that uses a
particular machinery mechanism aided human operators for
performing a task. Mechanization is the manual operation of a
task using powered machinery that depends on human decision
making.
On the other hand, automation replaces the human involvement
with the use of logical programming commands and powerful
machineries.
Industrial network and automation
Industrial network and automation
Industrial network and automation
Industrial Network Automation
 Industrial network and automation
Industrial Automation
Industrial Automation is the replacement with computers and machines to
that of human thinking. The word Automation gives the meaning ‘self
dictating’ or ‘a mechanism move by itself’ that derived from the Greek
words Auto and Matos where auto means self while Matos means moving.

In a brief, industrial automation can be defined as the use of

set technologies and automatic control devices that results the automatic
operation and control of industrial processes without significant human
intervention and achieving superior performance than manual control. These
automation devices include PLCs, PCs, PACs, etc. and technologies include
various industrial communication systems.
Industrial network and automation
Industrial Automation
 Industrial network and automation
Industrial Automation

Types of Industrial Automation Systems

1. Fixed or Hard Automation

2. Programmable Automation
3. Flexible or Soft Automation
 Industrial network and automation
Advantages

Advantages of Automation System

•To increase productivity

•To provide optimum cost of operation
•To improve product quality
•To reduce routine checks
•To raise the level of safety
 Industrial network and automation
INTRODUCTION

Today’s highly increasing competitiveness over the industry demands

high quality and most consistent products with a competitive price. To
address this challenge number of industries considering various new
product designs and integrated manufacturing techniques in parallel with
the use of automated devices.

One of the remarkable and influential moves for getting the solutions of
above mentioned challenge is the industrial automation. Industrial
automation facilitates to increase the product quality, reliability and
production rate while reducing production and design cost by adopting
new, innovative and integrated technologies and services.
 Industrial network and automation
Proprioceptive Sensors

To measure : Velocity, position and acceleration

 Industrial network and automation
Exteroceptive Sensors

To estimate: The position of

the objects present
 Industrial network and automation
Exproprioceptive Sensors

To measure: The position of the Robot body or parts