Pressure Sensor Calibration for Full ADC Resolution Utilization
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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
Calibration of pressure sensing devices by setting a reference voltage for the ADC and a resistance value for the voltage-dividing resistance, optimizing the ADC's operational range to match the specific characteristics of each sensor, thereby improving interoperability and resolution utilization.
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 response characteristics vary between sensors leading to suboptimal ADC resolution utilization
Solution Approach 1:
The patent applies preliminary action by performing calibration measurements during the manufacturing process to determine the optimal reference voltage and voltage divider ratio for each sensor before final assembly. This advance characterization allows the system to compensate for manufacturing variations and maximize ADC resolution utilization without slowing down production.
Solution Approach 2:
The patent changes parameters by adjusting the reference voltage and voltage divider ratio based on measured sensor characteristics. By varying these electrical parameters according to each sensor's specific response, the system optimizes the voltage range to fully utilize the ADC's resolution while maintaining consistent manufacturing processes.
2Device complexity
If a fixed reference voltage and voltage divider ratio are used for all sensors, then device complexity is reduced, but ADC resolution is not fully utilized due to sensor variations
Solution Approach 1:
The system performs preliminary characterization measurements during manufacturing to determine optimal reference voltage and voltage divider settings for each sensor. These pre-determined parameters are stored and used during operation, allowing the system to achieve optimized resolution utilization without adding complexity to the operational circuitry.
Solution Approach 2:
The system uses each sensor's own characteristics to determine its optimal configuration parameters. By measuring the sensor's response and automatically calculating the appropriate reference voltage and voltage divider ratio, the system enables self-optimization without requiring external intervention or complex additional circuitry.
3Measurement precision
If ADC reference voltage and voltage divider ratio are optimized for each sensor, then measurement precision is improved, but calibration time and processing increase
Solution Approach 1:
The patent performs the time-consuming calibration measurements and parameter optimization during the manufacturing process rather than during field operation. By completing the characterization and determination of optimal parameters upfront, the system achieves high measurement precision without incurring calibration time losses during actual use.
Solution Approach 2:
The system rapidly performs calibration measurements during manufacturing by using automated test equipment that can quickly characterize sensor response and determine optimal parameters. This approach rushes through the calibration process efficiently, minimizing the time investment while ensuring each sensor is optimally configured before deployment.
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.