Automated Shunt Calibration Using Programmable Power Source
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Solution Overview
Problem
The existing shunt calibration method for pressure sensors is complex and costly due to the need for various shunt resistor values tailored to specific sensor characteristics, leading to increased manufacturing and field support complexities.
Innovation Solution
A system and method for automatic shunt calibration using a programmable power source, switch, and Wheatstone bridge, where a resistor is connected between the Wheatstone bridge and the power source to induce an offset in the sensor output signal, with a controller adjusting the power source output to match a predetermined value, allowing for calibration within a specific range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple shunt resistor values are stocked to achieve accurate calibration for different sensor characteristics, then measurement precision is improved, but device complexity and manufacturing complexity increase
Solution Approach 1:
The patent applies parameter changes by using a programmable power source that can dynamically adjust its output voltage to match different sensor characteristics. Instead of stocking multiple fixed resistor values, the system changes the electrical parameters (voltage/current) of the power source to achieve accurate calibration for various sensor types, thereby reducing inventory complexity while maintaining precision.
Solution Approach 2:
The programmable power source serves multiple functions by being capable of outputting different voltage and current values suitable for calibrating various sensor characteristics. This single multi-functional device replaces the need for multiple specialized calibration components, simplifying the overall system while maintaining comprehensive calibration capability.
2Adaptability or versatility
If various shunt resistor values are stocked in the factory, then adaptability to different sensor characteristics is improved, but manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The system achieves adaptability through parameter changes in the programmable power source output rather than through physical component variety. The power source can be programmed to provide different calibration currents for different sensor types, eliminating the need for complex assembly processes involving multiple resistor values while maintaining full adaptability to different sensor characteristics.
3Measurement precision
If ideal shunt resistance values are used for calibration, then measurement precision is improved, but loss of time increases due to limited resistor values available
Solution Approach 1:
The patent introduces dynamics into the calibration process through a programmable power source that can dynamically adjust its output in real-time to match the precise requirements of different sensors. This dynamic adjustment capability eliminates the time loss associated with selecting from limited pre-stocked resistor values, as the ideal calibration parameters can be achieved instantly through programming rather than physical component selection.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach simplifies the calibration process by allowing for automatic adjustment of the sensor output to a predetermined value, reducing the need for multiple resistor values and streamlining the manufacturing and field support processes.
Implementation Method 1
the switch may be used for connecting the resistor between the Wheatstone bridge and a power source output to induce an offset in the sensor output signal
Implementation Method 2
a pressure sense element that is configured to detect a pressure of a media to be sensed by converting mechanical stress caused by the incoming pressure of the media into an electrical output signal
Data Source
AI summary
A sensor assembly may include a Wheatstone bridge with one or more sense elements, an amplifier coupled to the Wheatstone bridge for providing a sensor output signal, a resistor, and a switch for connecting the resistor between the sensor and an adjustable power source output to induce an offset in the sensor output signal. In some instances, a controller may perform an automatic shunt calibration procedure by activating the switch to connect the resistor between the sensor and the adjustable power source output to induce an offset in the sensor output signal. The controller may read the output value and compare the output value with a predetermined value. The controller may adjust the power source output to a value that moves the sensor output value toward the predetermined value. The controller may repeat the reading, comparing and adjusting step until the sensor output value is within a predetermined range of the predetermined value.