Sensor Measurement Fundamentals Series

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 How to Build Better Test Systems for Load,
Pressure, and Torque

Aaron Ortbals
Product Manager
National Instruments
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 Measurement Components

Signal
Sensor Computer
Conditioning

Physical Analog-to-Digital
Connectivity
Measurement Converter

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 Measurement Components

Signal
Sensor Computer
Conditioning

Physical Analog-to-Digital
Connectivity
Measurement Converter

ni.com
 Wheatstone Bridge
• The gage resistance changes as strain is induced.
L R
Strain    
Strain-Gage Energy Transformation L R
• Gage factor is the ratio of resistance change to strain change. A specific DR in the gage =
Resistance of a Conductor
specific DL on the base material.
L
R =  R R
A
where: R = Resistance  R  RF
Gage _ Factor  F  R  R 
+ increased resistance = increased output
 = Resistivity
L 
L = Length L
Ohms A = Area (x Section)

Gage Factor (K)

Vout
R R
Vin
RG RG
K = 
L 

L Vout  VB  VD
where: = Resistance change
= Gage Resistance
= Strain
- Decreased resistance = increased output

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 Understanding Pressure Sensors
• Pressure is defined as force per unit area
• All pressure sensors use a force-summing device to convert the pressure into a stress or displacement
proportional to the pressure
• The stress or displacement is then applied to an electrical transduction element to generate the required
signal
• The examples below are generally related to silicon piezo resistive pressure

Pressure Deformation of Sense Change in Change in

(force/area) Element Electrical
Output
Properties
Examples…

RB-∆R RB+∆R

RB+∆R
RB-∆R

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 Piezoresistive Pressure Sensors
• In piezoresistive pressure sensors, the transduction elements that convert the stress from the diaphragm
deflection into an electrical signal are piezoresistors
• Piezoresistance = changing electrical resistance due to mechanical stress
• As shown here, typically 4 piezoresistors are used—connected in a Wheatstone bridge circuit—to
provide an output that changes primarily with pressure

Piezoresistors

Top View

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 Foil-Based Pressure Sensors
Two basic types of foil-based pressure sensors
•Diaphragm
•Force Sensor-based

Mechanical
Transmitter
Strain Gages
Strain Gages
Single Diaphragm

Gaged Element

Pressure Port

Pipe
Fluid Under Pressure

Fluid Under Pressure

Gaged Diaphragm Gaged Force Sensor With Mechanical Transmitter

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 Understanding Load Cells
• Load cells measure direct force
• Strain gage technology is a key function of load cells
• The structure (spring element) is the most critical component
-Multiple-bending beam design
-Multiple-column design
-Shear-web design
•Load cells feature duty cycle ratings
-Fatigue resistant
-General purpose

Multiple-Bending Beam
Multiple Bending Beam
Multiple-Column Design Shear Web Design Strain Gage
Design
Load Cells
Multiple-Column Load Cells
(Wheatstone Bridge or Electrical Circuits)
Shear-Web Load Cells
Low capacity: 20 – 20K N High Capacity:
High capacity:25
110K – 9M
KLbs. N kLbs.
to 2000 Capacity: 2K – 1M N
Low Capacity: 5 to 5,000 Lbs. Capacity: 500 to 200 kLbs.

P P
C T
T C
T T

Vout
C C C T
T C

C T
C C

T
T
T
C T
C
P Vin

Multi-column load cell for Spring element in wheel form, with

4Wheel-shaped spring
active arms with pairs element,
subjected to 4 activeincreased
arms incapacity.
uniaxial stress 4 active arms
radial webs withtopairs
subject directsubjected
shear.
adaptable to low profile trasducers.
equal and opposite strains field—2 aligned with maximum to equal
 and
 opposite strains
Four active gages with
pairs subjected to equal
Four active gages in  
strain, 2 “Poisson” gages
and oposite strains
Four active gages with  v (beam in bending or
  uniaxial stress field    shaft in torsion).
pairs subjected to equal   two aligned with maximum
  and oposite strains
v 
principal strain, two
(beam in bending or "Poisson" gages (column).
  shaft in torsion).

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 Types of Load Cells
3 Main Categories of Load Cells
•Bending beam
•Shear beam
•Column

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 Understanding Torque
What is torque? What is a torque sensor?
Torque = Force * Distance
A torque sensor measures the twist or windup between a rotating
drive source and load source such as an engine crankshaft or a
4 Main Torque Sensor Designs bicycle pedal.
•Hollow cruciform
•Solid square shaft
•Radial spoke
•Hollow tubular

T T
Hollow
Tubular
T
Radial
Radial
Spoke
Spoke
45°

Hollow
Hollow Solid
Solid
Cruciform
Cruciform Square
Square
Shaft
Shaft Tr

Tr Tr

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 Types of Torque Sensors
Reaction Torque Sensors

Rotary Torque Sensors

• Slip ring
• Rotary transformer
• Telemetry

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 Rotary Torque Sensors: Slip Ring

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 Rotary Torque Sensors: Rotary Transformer

SIGNAL EXCITATION
TRANSFORMER TRANSFORMER

STATIONARY PRIMARY
WINDING (TYP)
MAGNETIC
STRUCTURE ROTATING SECONDARY
WINDING (TYP)

STRAIN GAGED
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 Rotary Torque Sensors: Telemetry

Digital Telemetry As a System

Increase ….
• Performance
• Flexibility
• Scope of application

Reduce ….
• Installation time
• Product weight and size
• Initial cost and the cost of
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 Measurement Components

Signal
Sensor Computer
Conditioning

Physical Analog-to-Digital
Connectivity
Measurement Converter

ni.com
 Measurement Components

Signal
Sensor Computer
Conditioning

Physical Analog-to-Digital
Connectivity
Measurement Converter

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 Honeywell  NI Connectivity

Honeywell Sensors TEDS-Enabled Cable Assembly NI 9237

(from Honeywell)

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 TEDS Technology
• IEEE standardized template
• Stores sensor-specific information in EPROM onboard
sensor
• Instrumentation must be able to read TEDS chip

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 TEDS Advantages
• Sensor tracking
• Calibration periods
• Tie data back to a specific sensor
• Reduce system configuration time
• Scale and calibration information automatically loaded into
software
• Plug any sensor cable into any instrument channel
• Store sensor location in “user data”
• Eg. “hydraulic press feedback sensor,” “left wingtip force”

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 Measurement Components

Signal
Sensor Computer
Conditioning

Physical Analog-to-Digital
Connectivity
Measurement Converter

ni.com
 Measurement Components

Signal
Sensor Computer
Conditioning

Physical Analog-to-Digital
Connectivity
Measurement Converter

ni.com
 Measurement Components

Signal
Sensor Computer
Conditioning

Physical Analog-to-Digital
Connectivity
Measurement Converter

NI 9237

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 Measuring Bridge-Based Sensors
• Excitation to power the bridge
• ADC to measure signal

• Remote sense (optional)

• Shunt calibration (optional)

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 Excitation
To detect a change in resistance, voltage (excitation) must be applied.

Voltage Measurement
(to instrument)

Excitation
(from instrument) Vout
Vin

Diagram of Full Bridge Inside Load, Pressure, or Torque Sensor

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 Example Device Pinout

SC = Shunt Calibration
AI = Signal Input
RS = Remote Sense
EX = Power for Sensor
T = TEDS Communication

Unique to NI 9237. Provides external excitation

input to pass through to sensors (optional).

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 Ratiometric Bridge Measurements

Traditional Approach Ratiometric Approach

Advantages
• High accuracy and low susceptibility to excitation temperature drift
• Reduced regulation design requirements allowing for increased channel count

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High Resolution ADC
Weighing nickels with a load cell
 Hardware Demonstration

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 Software Demonstration

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NI Solutions for Bridge Measurement
NI CompactDAQ PXI

• NI 9237 universal strain module • NI PXIe-4330 universal strain module

• NI 9235/36 high-density quarter-bridge
modules

• Best accuracy
• Rugged, compact • Best synchronization
• USB, wireless, Ethernet • Highest bandwidth
• Synchronized

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 ni.com/data-acquisition

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