UNIT: 5

Smart sensors or Intelligent Sensors: Smart sensors or intelligent sensors are

sensors with integrated electronics that can perform one or more of the following function:
1. Logic functions,
2. Two-way communication,
3. Make decisions
A smart sensor is simply one that acquires physical, biological or chemical input, converts the
measured value into a digital format and transmits that measured information via the Ethernet
to a computer monitoring point.

General Structure of Smart Sensors:

From the definition of smart sensor it seems that it is similar to a data acquisition system, the
only difference being the presence of complete system on a single silicon chip. In addition to
this it has on–chip offset and temperature compensation. A general architecture of smart
sensor consists of following important components:
1. Sensing element/transduction element,
2. Amplifier,
3. Sample and hold,
4. Analog multiplexer
5. Analog to digital converter (ADC),
6. Offset and temperature compensation,
7. Digital to analog converter (DAC),
8. Memory,
9. Serial communication and
10. Processor
Description of Smart Sensor Architecture:
1. Architecture of smart sensor is shown. In the architecture shown A1, A2…An are the
amplifiers and S/H1,S/H2…S/Hn are sample and hold circuit corresponding to different
sensing element respectively.
2. To get a digital form of analog signal, the analog signal is periodically sampled and that
constant value is held and is converted into a digital words.
3. Any type of ADC must contain a circuit that holds the voltage at the input to the ADC.
4. ADC starts conversion when it receives start of conversion signal (SOC) from the
processor and after conversion is over it gives end of conversion signal to the processor.
5. Outputs of all the sample and hold circuits are multiplexed together so that we can use a
single ADC, which will reduce the cost of the chip.
6. Dedicating two channels of the multiplexer and using only one ADC for whole system can
avoid the addition of ADC. This is helpful in offset correction and zero compensation of gain
due to temperature changes.
7. In addition to this smart sensor also include internal memory so that we can store the data
and program required.

Characteristics of Smart Sensors:

1. Self-Calibration:
1. Smart sensors acquire information about a non-electrical quantity and convert this
information to a useful electrical output signal. The sensing element performs the conversion
from the non-electrical domain to an electrical signal, while the interface electronics further
process this signal to produce an output that can be used in a measurement or control system.
2. Errors introduced in these steps affect the performance and reliability of the overall system.
Therefore, it is very important to determine how large these errors are. The process of doing
so is generally referred to as calibration.
3. Self-calibration is to adjust the deviation of the output of sensor from the desired value
when the input is at minimum. Calibration is needed because their adjustments usually
change with time that needs the device to be removed and recalibrated.
4. Users of conventional (non-smart) sensors typically need to obtain calibration coefficients
from the manufacturer to be able to interpret the output signal of the sensor. In modern smart
sensors, in contrast, such coefficients are often programmed into the sensor, and a corrected
output signal is provided to the user. This makes the use of such sensors easier.

2. Self-Testing of faults
1. Smart sensors perform self-testing by monitoring internal signals for evidence of faults.
2. It is difficult to achieve a sensor that can carry out self-testing of all possible faults, but it is
possible to make simple checks that detect many common faults.
3. One example of self-diagnosis in a sensor is measuring the sheath capacitance and
resistance in insulated thermocouples to detect breakdown of the insulation. Usually, a
specific code is generated to indicate each type of possible faults.
4. One difficulty that often arises in self-diagnosis is in differentiating between normal
measurement deviations and sensor faults.

3. Self-communication:
1. The most important feature of a smart sensor is the ability to communicate, which can be
done by displaying the data directly to the user and transfer it over a wired interface
wirelessly.
2. These sensors can transmit a binary code by using a diode LED (power on/off), colour
changing indicator, or a liquid crystal display (LCD).
3. The LCD screens can display characters, symbols or graphics, and they can be larger and
more complex as the complexity of data to get transferred increases.
4. The wireless communication is provided according to several international standards that
are Bluetooth, UWB, ZigBee and Wi-Fi. Each of these standards has different data
throughputs and ranges.
4. The use of these standards depends on their purpose; for example, Bluetooth is used for
shorter distance communications, while Zigbee are used for indoor and outdoor multinode
network applications.
Application of Smart sensors:
1. Automatic Robot Control:

A robot, however, is supposed to be a flexible and more or less intelligent tool, able to
perform a variety of tasks and responsive to varying environmental conditions.
1. The control system of the robot must be provided with information that is not available in
the teaching phase. Such information should be supplied by appropriate sensors, monitoring
the world outside the robot.
2. Robotic sensors are used to estimate a robot's condition and environment. These signals are
passed to a microcontroller to enable appropriate behaviour.
3. Sensors in robots are based on the functions of human sensory organs. Robots require
extensive information about their environment in order to function effectively.
4. Sensors provide analogs to human senses and can monitor other phenomena for which
humans lack explicit sensors.
a. Simple Touch: Sensing an object's presence or absence.
b. Complex Touch: Sensing an object's size, shape and/or hardness.
c. Simple Force: Measuring force along a single axis.
d. Complex Force: Measuring force along multiple axes.
e. Simple Vision: Detecting edges, holes and corners.
f. Complex Vision: Recognizing objects.
g. Proximity: Non-contact detection of an object.
Sensors can measure physical properties, such as the distance between objects, the presence
of light and the frequency of sound. They can measure:
 Object Proximity: The presence/absence of an object, bearing, color, distance
between objects.
 Physical orientation. The co-ordinates of object in space.
 Heat: The wavelength of infrared or ultra violet rays, temperature, magnitude,
direction.
 Chemicals: The presence, identity, and concentration of chemicals or reactants.
 Light: The presence, color, and intensity of light.
 Sound: The presence, frequency, and intensity of sound.

Motion controllers, potentiometers, tacho-generators and encoder are used as joint

sensors, whereas strain-gauge based sensing is used for contact force control.
Internal sensor*
It is the part of the robot. Internal sensors measure the robot's internal state. They are used to
measure position, velocity and acceleration of the robot joint.
Position sensor: Position sensors measure the position of a joint (the degree to which the
joint is extended). They include:
• Encoder: A digital optical device that converts motion into a sequence of digital
pulses.
• Potentiometer: A variable resistance device that expresses linear or angular
displacements in terms of voltage.
• Linear variable differential transformer: A displacement transducer that provides
high accuracy. It generates an AC signal whose magnitude is a function of the
displacement of a moving core.
Velocity Sensor: A velocity or speed sensor measures consecutive position measurements at
known intervals and computes the time rate of change in the position values.

2. Automobile engine control:

Today’s modern automobiles have a variety of sensors. These sensors built into their engine
to ensure that the owner can identify and prevent possible issues before they result in
breakdowns. These automobile engine sensors also ensure that the vehicle is operating at its
most efficient.
a. The Mass Air Flow Sensor (MAF):
The Mass Air Flow Sensor (MAF) is a computer-controlled sensor that calculates the volume
and density of the air taken in by the engine. This ensures that right amount of fuel is used for
optimized operating conditions. If this sensor is faulty, then fuel usage will be higher than
necessary.
b. The Engine Speed Sensor
Engine Speed Sensor is attached to the crankshaft and monitors the spinning speed of the
crankshaft, which controls the fuel injection and timing of the engine.
c. Oxygen Sensor
The Oxygen sensor measures the amount of unburden oxygen that is present in the exhaust
pipe. A faulty oxygen sensor will cause the car to idle poorly and jerk as well as cause high
fuel consumption.
d. Manifold Absolute Pressure Sensor
A Manifold Absolute Pressure Sensor, or MAP, senses the engine load. This is important for
the engine to be able to adjust the fuel injection based on the change in pressure.
e. Spark Knock Sensor
A spark knock sensor ensures that the fuel is burning smoothly. Detonation can cause the
head gasket to fail, piston lands to crack and rings to break, as well as possible rod bearing
damage.
f. Fuel Temperature Sensor
The Fuel Temperature Sensor is another sensor that ensures your cars fuel consumption is at
its most efficient. The colder the fuel is the more dense and the slower it burns while when
the fuel is warm is burns faster.
g. Voltage Sensor
Another important part in car sensors list is the Voltage Sensor. This sensor manages the
idling speed of the car and ensures the speed is increased or decreased as necessary.

Below is a list of popular car engine sensors used in modern vehicles:

S. Sensor Main Function
No
.
1. The Mass Air Flow Sensor Calculates the density and the volume of the air taken in
by the engine
2. The Engine Speed Sensor Monitors the spinning speed of the crankshaft
3. Oxygen Sensor Measures the amount of unburden oxygen presented in
the exhaust pipe
4. Manifold Absolute Pressure Measures the manifold pressure inside and outside
Sensor
5. Spark Knock Sensor Ensures that the fuel is burned correctly
6. Fuel Temperature Sensor Ensures the right amount of fuel is injected to keep the
motion smoothly
7. Voltage Sensor Manages the car speed and ensures the speed is
controllable

3. Optical sensor: Optical sensor is one of the examples of smart sensor, which are used
for measuring exposure in cameras, optical angle encoders and optical arrays.

4. Accelerometer: Accelerometer consists of the sensing element and electronics on

silicon chip. The accelerometer itself is a metal-coated SiO2 cantilever beam that is
fabricated on silicon chip where the capacitance between the beam and the substrate provides
the output signal.

4. Reduced cost of bulk cables and connectors:

Use of smart sensor has significantly reduced the cost of bulk cables and connectors needed
to connect different blocks (i.e. electronic circuits).

5. System Reliability:
System reliability is significantly improved due to the utilization of smart sensors. One is due
to the reduction in system wiring and second is the ability of the sensor to diagnose its own
faults and their effect.

6. Better Signal to Noise Ratio:

The electrical output of most of the sensors is very weak and if this transmitted through long
wires at lot of noise may get coupled. But by employing smart sensor this problem can be
avoided.

7. Improvement in characteristics:
Non-linearity:
Many of the sensors show some non-linearity, by using on-chip feedback systems or look up
tables we can improve linearity.
Cross-sensitivity:
Most of the sensors show an undesirable sensitivity to strain and temperature. Incorporating
relevant sensing elements and circuits on the same chip can reduce the cross sensitivity.