Sensor Module Fabrication and Calibration Process
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Solution Overview
Problem
The high cost and time-consuming nature of calibrating sensor modules, particularly temperature sensors, to ISO 17025 standards leads to equipment downtime and low adoption rates in industries with stringent regulatory requirements, such as the food and healthcare sectors.
Innovation Solution
A combined fabrication and calibration process for sensor modules, involving a substrate with continuous traces and sensor chips, where the substrate is tested under controlled conditions with a data collection apparatus to compare sensor values to reference values, allowing for simultaneous fabrication and calibration of pre-calibrated sensor modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensor modules are calibrated to ISO 17025 standards, then measurement precision is improved, but loss of time and manufacturing cost increase
Solution Approach 1:
The calibration process is segmented into automated individual sensor calibration steps performed during manufacturing, followed by statistical process control validation. This allows precise calibration of each sensor module while reducing overall time through parallel processing and elimination of manual procedures.
Solution Approach 2:
Calibration is performed as a preliminary action during the manufacturing process itself, rather than as a separate post-manufacturing step. Sensor modules are calibrated immediately after assembly, ensuring accuracy is built-in from the start and eliminating subsequent calibration downtime.
2Measurement precision
If sensor modules are calibrated to ISO 17025 standards, then measurement precision is improved, but manufacturing cost increases
Solution Approach 1:
The calibration process is segmented into automated individual sensor calibration steps performed during manufacturing, followed by statistical process control validation. This allows precise calibration of each sensor module while reducing overall time through parallel processing and elimination of manual procedures.
Solution Approach 2:
The system performs self-calibration using internal reference measurements and statistical process control algorithms. The automated calibration system validates its own results through repeated measurements and statistical analysis, eliminating the need for expensive external ISO 17025 accredited calibration services while maintaining high accuracy standards.
3Manufacturing precision
If conventional production processes are used, then device complexity is reduced, but manufacturing precision deteriorates
Solution Approach 1:
The calibration process incorporates continuous feedback through statistical process control, where each sensor's measurements are compared against reference values and process specifications. The system automatically adjusts calibration parameters based on measured deviations, ensuring high precision while managing complexity through algorithmic control rather than manual intervention.
Solution Approach 2:
Manual mechanical calibration procedures are replaced with automated electronic calibration systems that use digital signal processing and statistical algorithms. This substitution increases precision through consistent automated measurements while managing complexity through software-based control rather than complex mechanical adjustment mechanisms.
Data Source
AI summary
The present disclosure provides a combined fabrication and calibration process for sensor modules and temperature sensor modules in particular. The present disclosure also provides the completed calibrated sensor module and an electronic device containing the calibrated sensor module.