Research Paper
Research Paper
Sensors & Transducers Journal (ISSN 1726-5479) is a peer review international journal published monthly online by International Frequency Sensor Association (IFSA).
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Sensors & Transducers Journal
Contents
Volume 136 www.sensorsportal.com ISSN 1726-5479
Issue 1
January 2012
Research Articles
A Data Acquisition System Based on DSP for Mechanical Nanoscale Displacement Sensor
Yong Yu, Qian Wu, Hanyu Sun, Zhengwei Li and Yunjian Ge .......................................................... 12
Fiber Optic Vibration Sensor Using Pmma Fiber for Real Time Monitoring
P. Kishore, D. Dinakar , D. Sen Gupta, P. Saidi Reddy, M. Sai Shankar, K. Srimannarayana ......... 50
A Decoupling Algorithm Based on Homotopy Theory for 3-D Tactile Sensor Arrays
Junxiang Ding, Yunjian Ge, Yuan Wang, Zhaohui Wang .................................................................. 72
An Embedded Web based Real Time Application for Remote Monitoring & Controlling of
MST RADAR Transmitters
Nagabhushan Raju Konduru, Lakshmi Narayana Roshanna, Rajendra Prasad Thommundru,
Chandrasekhar Reddy Devanna ........................................................................................................ 96
Authors are encouraged to submit article in MS Word (doc) and Acrobat (pdf) formats by e-mail: [email protected]
Please visit journal’s webpage with preparation instructions: http://www.sensorsportal.com/HTML/DIGEST/Submition.htm
Abstract: In order to achieve high quality of products at lesser cost, accurate measurement of different
process variables is of vital importance in any industry. There are different well-established techniques
of measurement and control instrumentations of these variables. In the resistive transducer like strain
gauge, the small resistance generally changes linearly with a process variable like pressure but their
measurement by usual AC Wheatstone bridge circuit may suffer from errors due to the effect of stray
capacitance between bridge nodal points and ground and stray inductance on the strain gauge grid
respectively. Though the conventional Wagner-Earth technique may be used to reduced the error but
not suitable for continuous measurement. In the present paper, a modified operational amplifier based
AC Wheatstone bridge measurement technique has been proposed in which the effect of stray
capacitance and inductance is minimized. This bridge performance has been studied experimentally
with the strain gauge type pressure transducer. The linear characteristics over a wide range of pressure
with good repeatability, linearity and variable sensitivity have been described. Copyright © 2012
IFSA.
1. Introduction
Pressure is one of the important variables, which is required to measure and control in any process
industry. The pressure is measured by the different types of pressure measuring transducers [16, 17],
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Sensors & Transducers Journal, Vol. 136, Issue 1, January 2012, pp. 25-34
[18] such as Pirani Gauge, Thermocouple Gauge, Ionization Gauge, Potentiometer type, Piezoelectric
type, Optical Pressure Transducer etc. These types of pressure transducer have longer life period but
they comparatively require various environmental and experimental precaution during the
measurement. Mechanical Pressure Elements, several simple pressure sensing elements [1, 2, 4] are
used as the interface between the source of pressure and the instrument. Actual values of pressure are
inferred by their effects on the pressure sensors [1, 2, 3] such as force [15] or position, so that pressure
values may be transduced and expressed in terms of electric [7, 9], pneumatic [3], or hydraulic signal
that can be transmitted and served as the basis for indicating, recording and controlling pressure [7],
[11, 13].
In industry, a number of process variables like level, pressure, and force related variable etc. are
measured by using the resistive transducers. The resistances of these transducers are generally very
small and the stray capacitance and inductance between the ground and the bridge nodal points and on
strain grid may produce measurement error since they become sometimes comparable with the
impedance of the transducer being measured. In order to minimize this error, different types of
balancing techniques and precautions along with some special techniques like Wagner earth technique
have been proposed by various investigators. A modified approach of the balancing techniques of ac
Whetstone’s bridge network have been reported by E. Takagishi [23] where as D. Moriali et al [24]
and P. Holmberg [25] have proposed self balancing techniques to achieve high accuracy in
measurement.
In the present paper a low cost modified operational amplifier based AC Wheatstone bridge technique
has been proposed for the minimization of the effect of stray capacitance without the use of Wagner-
earth technique. In this method the bridge nodal points of the bridge output lead wires are both kept at
virtual ground potential so that the effect of stray capacitance between the bridge output lead wires and
also between any outputs lead wire and ground may always be assumed to be negligible. The bridge
balance equations of this modified AC Wheatstone bridge network are also identical with that of the
conventional AC Wheatstone bridge network. Thus the continuous measurement may be possible by
this modified AC Wheatstone bridge network. Moreover this technique also provides an additional
bridge sensitivity factor adjustment by a linear potentiometer.
In the present investigation, the experimental work has been conducted by developing resistive strain
gauge type pressure transducers and the observed calibration curve and % error curve in terms of the
bridge components for the different values of the bridge sensitivity factor potentiometer have been
obtained and are reported in the present paper.
2. Method of Approach
The pressure measurement system contains the blocks as shown in Fig. 1, which are described below.
Process tank is cylindrical type Pressure container, which is nine inch long & ten inch diameter.
Output from the control valve acts as input line at the left hand side of the tank. A T- connector is
connected with input line for division input into two lines. One input line is connected to process tank
and other is connected to pressure sensor that is diaphragm. At the right hand sides an exhaust valve is
provided on process tank to adjust process load. Pressure gauge is provided on process tank to monitor
the pressure. A safety valve is mounted on the process tank.
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Sensors & Transducers Journal, Vol. 136, Issue 1, January 2012, pp. 25-34
Pressure to displacement sensor is a diaphragm element. Diaphragm is popular because they require
less space, producing sufficient motion for operating electrical transducer. It is so designed that
deflection vs. pressure characteristic must be linear. Deflection depends on the following factors:
Diameter;
Metal thickness;
Modulus of elasticity;
Applied pressure.
The diaphragm element is connected right hand side of the process tank. A strain gauge is pasted at the
center of the diaphragm & another strain gauge is pasted near the end of the circular diaphragm. The
diaphragm is deflected when the pressure is increased.
2.3. Transducer
Strain gauge is used as a secondary element for pressure sensing through diaphragm and supported
directly by sensing diaphragm acting as restoring agents. Here a modified operational amplifier based
quarter AC Wheatstone Bridge measurement technique is proposed for the measurement in pressure
change. Here two fixed resistances are used as the two arms of the bridge and two strain gauges are
used as the rest two arms. This resistance may change only a fraction of a percent for the full force
range of the gauge, given the limitations imposed by the elastic limits of the gauge material and of the
test specimen. Forces which are great enough to induce greater resistance changes would permanently
deform the test specimen and/or the gauge conductors themselves, thus ruining the gauge as a
measurement device. Thus, in order to use the strain gauge as a practical instrument, small changes in
resistance have to be measured with high accuracy. One of the most common ways of producing such
a change is to use a strain gauge, which changes it’s resistance with the movement of the diaphragm.
The diaphragm is usually made of a highly carbon steel.
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Sensors & Transducers Journal, Vol. 136, Issue 1, January 2012, pp. 25-34
3. Stress Analysis
The direction of principal stress of the circular diaphragm have been analyzed using the software
ANSYS as shown in Fig. 2. ANSYS helps designers and engineers around the world to really visualize
their ideas. With this software, developers and engineers can see a simulation of their design concept
on computer before a prototype is built. The diameter of the diaphragm used in this experiment is
86mm and thickness of the diaphragm is 0.42 mm. The computerized models are analyzed for their
response to combinations of such physical variables as stress, pressure, impact, temperature, and
velocity. This is very much useful for orientation and alignment of the strain gauge on the diaphragm.
4. Principle of Operation
A general AC Wheatstone bridge network is modified as shown in the Fig. 3, where two very high
gain operational amplifiers A1 and A2 are connected with the bridge network and the non-inverting
terminal connected to the circuit common or ground.
This enables the bridge output nodal points B and D to be almost at the same potentials with respect to
the ground and hence the effect of stray capacitance that will exist between them and also between
them and ground and stray inductance of the inductive coil may be assumed to be minimized.
Since B and D are at virtual ground, so for the sinusoidal supply voltage V=Vm sin t, the currents
through the bridge impedances Z1, Z2, Z3 and Z4 are respectively given by,
V V V V
I1 I2 I3 1 I4 1 (1)
Z1 , Z2 , Z 3 and Z4
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Sensors & Transducers Journal, Vol. 136, Issue 1, January 2012, pp. 25-34
A1
C'
C'
A2
C'
If V0 be the output voltage of the operational amplifier A2 then the current through its feedback
resistance is given by
V0
If (2)
Rf
.
I1 I 3 0 (3)
and
I2 I4 I f 0 (4)
.
V V1 Z
0 V1 3 V (5)
Z1 Z 3 or Z1
V V V
1 0 0 (6)
Z2 Z4 Rf
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Sensors & Transducers Journal, Vol. 136, Issue 1, January 2012, pp. 25-34
Rf
V0 Z 2 Z 3 Z1 Z 4 V (7)
Z1 Z 2 Z 4
i.e.,
Z1 Z 3
(8)
Z 2 Z 3 Z 1 Z 4 or Z 2 Z 4
This balance condition is identical with that of the conventional bridge network.
In the case of a strain gauge type resistive transducer, the change of resistance of the transducer is
generally measured by AC Wheatstone Bridge network. The measurement error due to the effect of
stray capacitance between the bridge nodal points and between the lead wires and stray inductance of
the strain grid may be minimized by using modified networks as shown in Fig. 4.
Z 1 R1 , Z 2 R2 , Z 3 R3 R3 , Z 4 R4 (9)
and R3 is the resistance of the resistive transducer for the minimum value of the process pressure
being measured and R3 is the change in resistance for a given change of the process pressure above
this minimum value.
Hence from the equation no. (7), the bridge output voltage is given as
V0 [ R2 ( R3 R3 ) R1 R4 ]V
Rf
R1R2 R4 (10)
or
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Sensors & Transducers Journal, Vol. 136, Issue 1, January 2012, pp. 25-34
V0 [( R2 R3 R1 R4 ) R2 R3 ]V
Rf
R1R2 R4
If the bridge is balanced at the minimum value of the process variable for which the transducer
resistance is R3 (R3 = 0), then V0=0
So
Hence from the equation nos. (10) and (11), the bridge output voltage for a change in resistance R3 by
the change in process variable above the minimum value is given by –
V0 .R3 .V
Rf
R1R4 (12)
V0 KR3 , (13)
where
K
RfV
R1R4 constant (14)
Or
V0 R3 (15)
i.e., output voltage is linearly related to the change in process variable if the transducer is linear.
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Sensors & Transducers Journal, Vol. 136, Issue 1, January 2012, pp. 25-34
6. Experimental Results
Experiments have been performed by using the modified AC Wheatstone Bridge set up with a
stabilized sinusoidal excitation signal at 1000 Hz using the laboratory standard equipments to find the
calibration characteristics of the transducer, signal conditioner. The transducer characteristics have
been determined with the help of CRO and true RMS digital multimeter as a detector and measuring
unit. The initial minimum bridge balance condition is obtained in zero pressure for a selected value of
Rf by varying the resistance of potentiometer i.e. R1 and R2 at a constant excitation frequency of
1000 Hz. The performance of the bridge network for a resistive transducer has been studied by
gradually increasing the pressure and thus the change in resistance (R3).
The bridge output voltage is taken by changing pressure for both increasing and decreasing modes.
From this readings % error is calculated. Variations of Unbalance Bridge output voltage with the
change in pressure and thus change in (R3) for different values of bridge sensitivity factor resistance
Rf
and % error curves are shown in Fig. 6 and Fig. 7 respectively.
Rf = 5 kohm Rf = 10 kohm
Rf = 15 kohm Rf = 20 kohm
400
Bridge output in mV
350
300
250
200
150
100
50
0
0,0 0,2 0,4 0,6 0,8 1,0 1,2 1,4
Rf=5 Kohm
Rf=20 Kohm
0,2000
0,1000
0,0000
-0,1000 0 0,2 0,4 0,6 0,8 1 1,2 1,4
-0,2000
-0,3000
-0,4000
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Sensors & Transducers Journal, Vol. 136, Issue 1, January 2012, pp. 25-34
5. Discussion
There are different types of well aspect classical and modern technologies of measurement and control
instrumentation with very good accuracy. But most of the techniques are either costly or proprietary
product of manufacturers. So the basic aim of the present project is to develop low cost non-
conventional technique for accurate measurement of process variable like pressure. The maximum
excitation voltage of the strain gauge in the arm BC of the modified AC Wheatstone Bridge network in
Fig. 3 depends on the maximum output voltage (V1) of the op-amp A1. To obtain the optimum
sensitivity the bridge arms impedances should be selected to be nearly identical like all other bridge
networks. Before connecting the ground with the common terminal of the network, care is taken so
that the ground wire is nearly at zero potential and the high ground potential may not damage the ICs.
The bridge balance condition is not found to disturb on account of any change of orientation of the
lead wires. From the experimental study, a good linearity and repeatability has been observed in the
AC Wheatstone bridge network for resistive pressure transducer. The error curve in Fig. 6 is showing
the percentage of deviation from linearity. This deviation is occurring mainly for the non-uniform
deflection of the diaphragm. The technique may also be used for the inductance, capacitance,
conductance or admittance type transducers.
The sensitivity of the bridge network may be varied by varying the potentiometer Rf as explained in
equation (10). Hence quarter/half Wheatstone bridge network can be used for the measurement of
strain gauge resistance instead of full bridge technique.
The whole network gives an amplified bridge output. Hence the use of a bridge amplifier or an
instrumentation amplifier may be avoided. The bridge output may be directly rectified and filtered to
obtain a DC voltage signal to be used by a transmitter, microprocessors based, micro-controller based
or PC based instrumentation system.
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Sensors & Transducers Journal
Sensors & Transducers Journal (ISSN 1726-5479) provides an advanced forum for the science and technology
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