Pressure Sensor Calibration Using Binary Search for ADC Range Matching
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Solution Overview
Problem
Variations in sensor manufacturing lead to different response characteristics among pressure sensors with the same specifications, resulting in suboptimal utilization of analog-to-digital converters (ADCs) and potential loss of resolution when used in identical pressure sensing devices.
Innovation Solution
A calibration process is implemented to set a reference voltage for the ADC and a resistance value for the voltage-dividing resistance, ensuring that the ADC operates within the optimal range of the sensor's characteristics, thereby improving interoperability and ADC resolution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sensors are manufactured with standard process variations, then production cost and manufacturing time are reduced, but sensor response characteristics vary and ADC resolution is underutilized
Solution Approach 1:
The patent applies preliminary action by performing calibration during the manufacturing process to pre-determine the optimal ADC reference voltage and voltage-dividing resistance for each sensor based on its specific response characteristics. This ensures that when the sensor is deployed, the ADC is already optimized for that particular sensor, eliminating the need for post-manufacturing adjustments and maximizing resolution utilization from the start.
Solution Approach 2:
The patent utilizes parameter changes by dynamically adjusting the ADC reference voltage and voltage-dividing resistance values based on the measured response characteristics of each individual sensor. By changing these electrical parameters according to each sensor's unique characteristics, the system optimizes the utilization of ADC resolution while maintaining standard manufacturing processes.
2Device complexity
If a fixed ADC reference voltage and voltage-dividing resistance are used for all sensors, then device complexity is reduced, but ADC resolution is lost due to mismatched sensor characteristics
Solution Approach 1:
The patent implements self-service by enabling each sensor-ADC combination to self-optimize its configuration through an automated calibration process. The system measures the sensor's response characteristics and automatically determines the optimal ADC reference voltage and voltage-dividing resistance values without requiring manual intervention or complex external calibration equipment, thus maintaining device simplicity while improving measurement precision.
Solution Approach 2:
The patent applies feedback by using the measured sensor response characteristics to adjust the ADC configuration parameters. The calibration process measures the actual sensor output and uses this feedback information to determine the optimal reference voltage and resistance values, creating a closed-loop system that optimizes performance based on actual sensor behavior rather than theoretical specifications.
3Measurement precision
If individual calibration is performed for each sensor, then ADC resolution utilization is improved, but manufacturing time and process complexity increase
Solution Approach 1:
The calibration process is designed to be self-service, where each sensor calibrates itself through an automated measurement and adjustment process. The system automatically measures the sensor's response characteristics and configures the optimal ADC parameters without requiring manual intervention, significantly reducing the time and complexity associated with individual calibration while maintaining high resolution utilization.
4Ease of manufacture
If standard sensor specifications are used without customization, then ease of manufacture is improved, but interoperability between ADC and sensor is suboptimal
Solution Approach 1:
The patent applies parameter changes by adjusting the ADC reference voltage and voltage-dividing resistance values to match each sensor's specific response characteristics. This allows standard sensors to be optimally paired with ADCs through electrical parameter adjustment rather than physical customization, maintaining ease of manufacture while improving interoperability and ensuring each sensor-ADC pair operates at optimal performance.
Data Source
AI summary
Calibration of a sensing device is provided. The sensing device includes a sensor configured to sense a condition. In the sensing device, a voltage-dividing resistance and a reference voltage of an analog-to-digital converter are set to configure a quantization range of the analog-to-digital converter given characteristics of the sensor. During calibration, a binary search is performed between lower and upper limits of the voltage-dividing resistance, which is a variable resistance, to find the resistance of the voltage-dividing resistance at which the sensing device is operated.