🧭 Overview
🧠 One-sentence thesis
Different sensor technologies convert physical phenomena—strain, displacement, temperature, pressure, acceleration, and angular position—into electrical signals through specialized transduction mechanisms, each suited to particular measurement ranges, accuracies, and environmental conditions.
📌 Key points (3–5)
- Strain gauges measure micro-scale bending/flexing by changing resistance when stretched or compressed, typically used in Wheatstone bridge circuits.
- Displacement sensors (LVDT, potentiometric) measure linear or angular position changes through induction or variable resistance.
- Temperature sensors (thermocouples, thermistors) differ fundamentally: thermocouples generate voltage from dissimilar metals (μV/°C sensitivity, harsh environments), while thermistors change resistance (higher accuracy, lower temperature range).
- Common confusion: Thermocouple vs. thermistor—thermocouples work in extreme temperatures but need amplification and are less accurate; thermistors are very accurate (±0.1°C) but limited to ~300°C maximum.
- Ranging and motion sensors (ultrasonic, laser, accelerometers, encoders) measure distance, vibration, or rotation using time-of-flight, suspended mass deflection, or optical/magnetic pulse counting.
🔧 Strain measurement technology
🔧 How strain gauges work
Strain gauge: a resistive sensor that detects bending or flexing by changing resistance according to R = ρL/A when stretched or compressed.
- The resistive element changes in three ways under strain:
- Compression: element thickens (A↑) and shortens (L↓) → resistance decreases (R↓)
- Tension: element thins (A↓) and lengthens (L↑) → resistance increases (R↑)
- Piezoresistive effect: resistivity (ρ) itself increases under strain
⚖️ Gauge factor and strain calculation
The gauge factor (GF) describes sensitivity to deformation:
- For metal strain gauges, GF ≈ 2
- Formula: GF = (ΔR/R₀) / (ΔL/L)
- Strain = (Rₓ - R₀) / (R₀ · GF)
Sign convention:
- Positive strain (ΔR > 0) → tension
- Negative strain (ΔR < 0) → compression
Example: A strain gauge in a Wheatstone bridge is balanced at no-load by adjusting R₂. When loaded, measure Vₓ to find Rₓ, then calculate strain from the resistance change.
🌉 Bridge circuit implementation
- Strain gauge forms the fourth leg (Rₓ) of a Wheatstone bridge
- R₂ is often a precision potentiometer adjusted to balance the bridge (Vₓ = 0) under no-load
- Initial resistance R₀ = R₂ · R₃/R₁ when balanced
- After loading, use bridge equation to solve for Rₓ from the differential voltage
Don't confuse: The manual balancing method (adjust R₂ until Vₓ = 0 after loading) vs. the voltage measurement method (measure Vₓ and calculate Rₓ from Equation 4.2).
📏 Displacement and position sensors
📏 LVDT (Linear Variable Differential Transformer)
LVDT: a sensor using three coils and induction to measure rectilinear motion with micrometer accuracy over ranges up to several inches.
Operating principle:
- Central coil energized with AC creates alternating magnetic field in movable ferrite core
- Core induces voltage in two secondary coils based on overlap amount
- Differential voltage between secondary coils indicates core position
- Δx = k · ΔVout (where k is sensitivity in V/mm or V/in per excitation volt)
Key characteristics:
- Linear ranges from ±1 mm to ±50 cm
- Resolution essentially infinite (limited only by signal conditioning circuit's voltage detection)
- Typical linearity: ±0.25% over range
- No electrical contact between moving element and circuit
- Robust to extreme temperatures (used in aviation)
Don't confuse: Center position produces 0V differential, but any movement changes induced voltage in both coils—the LVDT measures the difference between the two secondary coils.
🎚️ Potentiometric sensing
A potentiometer is a three-terminal variable resistor:
- Two end terminals span the full resistive element (fixed resistance)
- Wiper terminal varies resistance as it moves across element
- Forms a voltage divider: V₀ = Vs · (x · Rpot)/Rpot = Vs · x
Common implementations:
- Single-turn rotary: 360° total rotation
- Multi-turn (e.g., 10-turn): 3600° total rotation for finer resolution
- Throttle position sensors in vehicles
Example: For a desired voltage range of 6–9V from a 12V supply across a 1000Ω potentiometer, the wiper position x ranges from 0.5 to 0.75 (50% to 75%). A 10-turn potentiometer provides 900° of adjustment vs. 90° for single-turn.
📡 Ranging and motion detection
📡 Ultrasonic ranging
Principle: Time-of-flight measurement using sound waves
- Range = ½ · speed of sound · Δt
- Speed of sound ≈ 340.29 m/s (varies with temperature: s = 331.5 + 0.6·T(°C))
- Transmitter and receiver co-located to minimize angle effects
- Practical range: typically under a few meters
Temperature sensitivity: At 20°C vs. 25°C, a 20 cm measurement differs by ~1 μsec in time—small variation but measurable.
🔦 Infrared and laser ranging
| Type | Range | Accuracy | Principle |
|---|
| IR | 2–80 cm | Limited, nonlinear | LED reflection to phototransistor |
| Ultrasonic | Few meters | Moderate | Sound time-of-flight |
| Laser | 20+ km (military) | High but not sub-mm | Light time-of-flight, Range = ½·c·Δt |
Don't confuse: Laser's much faster speed (c = 299,792,458 m/s) enables long-range measurement but prevents achieving ultrasonic-level precision at short distances.
📳 Accelerometers
Accelerometer: a sensor that measures acceleration (force per unit mass, a = F/m) by detecting displacement of a suspended internal mass.
Transduction methods:
- Piezoelectric: crystal deformation generates voltage (dynamic process only)
- Capacitive: mass displacement changes plate separation, altering capacitance (C = εA/d)
Key specifications:
- Bandwidth: maximum detectable vibration frequency (e.g., 10 Hz bandwidth cannot measure 20 Hz vibration)
- Sensitivity: typically V/G or mV/G (wider range reduces discrimination ability)
- Shock rating: maximum instantaneous G's before damage (e.g., from dropping)
Vibration measurement: Accelerometer on a flexing beam detects back-and-forth motion. For a mass-spring-damper system, the acceleration data reveals:
- Resonance frequency (from peak intervals or spectral analysis)
- Decay rate (from exponential fit of peak magnitudes)
Don't confuse: Single-supply accelerometers output positive voltage only; no-acceleration state has a DC offset that must be removed before analysis.
🔄 Encoders (angular position/velocity)
Optical encoders:
- IR LED beam passes through slotted wheel to phototransistor
- Beam blocked/passed as shaft rotates → square wave output
- Resolution = 360°/number of slits (e.g., 36 slits = 10°/step)
- Count pulses for displacement; measure frequency for velocity
Magnetic encoders (Hall effect):
- Hall effect sensor detects magnetic field strength
- Magnets on rotating wheel generate voltage pulses as they pass sensor
- Latching digital sensors toggle between 0V and VCC on polarity change
- Used for vehicle speed sensing (e.g., flywheel with multiple magnets)
Example: Wheel with 4 magnets requires 5 pulses for one complete revolution (starting magnet passes sensor again).
🌡️ Temperature sensing technologies
🌡️ Thermocouples
Thermocouple: two dissimilar metals joined together that generate voltage proportional to temperature due to the thermo-electric (Seebeck) effect.
Basic equation: Vₓ = kT(Tₓ - Tref)
- Sensitivity kT typically in μV/°C range
- Requires reference junction (often ice bath at 0°C) or cold-junction compensation
- Linear approximation often used, but reference charts provide better accuracy
Common types and ranges:
| Type | Range (°C) | Accuracy | Materials |
|---|
| K | -270 to 1260 | ±2.2°C or ±0.75% | Nickel-Chromium/Nickel-Alumel |
| J | -210 to 760 | ±2.2°C or ±0.75% | Iron/Constantan |
| T | -270 to 370 | ±1.0°C or ±0.75% | Copper/Constantan |
| E | -270 to 870 | ±1.7°C or ±0.5% | Nickel-Chromium/Constantan |
Signal conditioning needs:
- External amplification required (μV-level signals)
- Lowpass filtering for noise reduction and anti-aliasing
- Calibration must account for amplification gain
Don't confuse: Some thermocouples are linear over full range (Type E above 0°C), others are not (Types S and B)—use only in guaranteed linear region or apply corrections.
🌡️ Thermistors
Thermistor: a thermally sensitive resistor with pronounced resistance change with temperature.
Two types:
- NTC (Negative Temperature Coefficient): resistance decreases as temperature increases (inverse relationship)
- PTC (Positive Temperature Coefficient): resistance increases with temperature (direct relationship)
B-value equation: B(T₁/T₂) = (T₂ × T₁)/(T₂ - T₁) × ln(R₁/R₂)
- Temperatures in Kelvin (K = °C + 273.15)
- B-value specified for temperature range (e.g., B₁₀/₁₀₀ = 2552 for 10–100°C)
- Nominal resistance given at lower temperature
Comparison with thermocouples:
| Feature | Thermocouple | Thermistor |
|---|
| Accuracy | Moderate | Very high (±0.1°C) |
| Temperature range | Very wide (to 1700°C) | Limited (~300°C max) |
| Output | Voltage (μV/°C) | Resistance change |
| Linearity | Approximately linear | Nonlinear (exponential) |
Circuit configurations:
- Wheatstone bridge (preferred): More sensitive to small resistance changes, better accuracy
- Voltage divider (simpler): VT = Vs · Rthermistor/(R₁ + Rthermistor)
- NTC in lower position: VT decreases as temperature increases (inverse)
- Swap positions for direct relationship
🛡️ Temperature protection circuits
Comparator-based control:
- Voltage divider with thermistor feeds comparator
- Reference voltage (vref) sets threshold
- Output goes HI when temperature exceeds limit
- Can control cooling devices or shut down processes
MOSFET switching:
- Thermistor voltage divider drives MOSFET gate
- When gate voltage exceeds threshold (~2V for BS170), MOSFET turns on
- Can control LEDs, relays, or other loads
- Example: NTC thermistor heated → resistance drops → gate voltage rises → MOSFET conducts
🔩 Pressure and specialized sensors
🔩 Pressure sensor types and technologies
Pressure measurement categories:
- Gauge pressure: relative to atmospheric pressure
- Absolute pressure: relative to perfect vacuum
- Vacuum pressure: below atmospheric pressure
Transduction technologies:
- Capacitive: Parallel-plate capacitor where pressure deflects one plate, changing capacitance (C = εA/d)
- Piezoelectric: Crystal deformation generates voltage during pressure change (dynamic process only—requires integration for long-term measurement)
- Strain gauge: Pressure-sensing diaphragm deflection measured by strain gauge
- LVDT-based: Ferrite core coupled to pressure-sensing surface tracks deflection
Applications:
- Tank fluid level (pressure = fluid weight/volume)
- Automotive: MAP sensor (manifold absolute pressure for fuel control), tire pressure monitoring, oil pressure
- Aviation: altitude, control surface position (temperature-robust)
- Rotating machinery balance (spring-loaded LVDT detects eccentricity)
Don't confuse: Piezoelectric pressure sensors only generate voltage during deformation—stable pressure produces no output unless integrated over time.
🔌 Practical implementation considerations
🔌 Signal conditioning requirements
Different sensors need different conditioning:
- Thermocouples: Amplification (μV signals), lowpass filtering, cold-junction compensation
- Strain gauges: Bridge balancing, precision voltage measurement
- Thermistors: Bridge or voltage divider, comparator for protection circuits
- Accelerometers: DC offset removal (single-supply), lowpass filtering, gain adjustment
🎯 Sensor selection criteria
When choosing sensors, consider:
- Range: Physical phenomenon limits (temperature, displacement, acceleration)
- Accuracy: Thermocouple ±2°C vs. thermistor ±0.1°C
- Environment: Harsh conditions favor thermocouples, LVDTs; controlled environments allow thermistors
- Resolution: LVDT essentially infinite (circuit-limited); encoder depends on slot count
- Response time: Piezoelectric for dynamic only; capacitive for static and dynamic
- Cost: IR ranging most economical; laser most expensive but longest range
⚠️ Common measurement pitfalls
- Temperature effects: Ultrasonic ranging speed varies with temperature; must account for or control environment
- Linearity assumptions: Not all sensors linear over full range (thermocouples, thermistors)—verify operating region
- Calibration: Amplification gain must be incorporated; reference points needed (ice bath for thermocouples)
- Dynamic range matching: ADC resolution wasted if sensor range doesn't match input voltage range
- Noise sensitivity: Low-level signals (thermocouples) require careful shielding and filtering