Friday, January 3, 2020

I to V conversion. Convert 4-20mA to 1-5V, 0-5V, 1-10V, 0-10V

Current to Voltage converters or I to V converters as they are generally known are popular in process control applications where we need to interface output from transmitters to a data-acquisition system. Transmitter output are generally in 4 to 20 mA format which has to be converted to voltage form before feeding to a DAQ device.
In this post I will discuss about different circuits which convert 4-20 mA signals to 1-5V, 0-5V, 1-10 V and 0-10V form.
  • 4-20mA to 1-5VDC
This conversion can be simply implemented by using a precision 250 Ohm resistor.

The first circuit is a simple implementation of I-V converter. The value of resistor R is 250Ohm.
For 4 mA current, the voltage drop is 4*250 = 1V,
For 20 mA current, the voltage drop is 20*250 = 5V.

This circuit can load the current source (transmitter output DAC) when DAQ device or measuring meter is connected across the resistor causing error in measurement. By adding a buffer/ voltage follower, we are adding very input impedance across the resistor. This protects the source from getting loaded and provide accurate measurement of voltage drop.

One very common configuration of I-V converter using Op-amp is as below. The load is floated in this case.
At the output stage, inverting op-amp is used to get 1-5Volt.

  • 4-20 mA to 0-5 VDC
Just by changing the resistor value to 312.5 Ohm and adding an adder circuit with -1.25 V offset voltage, we can convert 4-20 mA to 0-5 VDC. The schematic is shown below.

  • 4-20 mA to 0-10 VDC
The circuit is same as above, only the value of resistor is changed to 625 Ohm and offset voltage is set to -2.5 VDC.

There is one more way of getting 0-10V. Here we will use 0-5VDC circuit with slight modifications. The op-amp is used in non-inverting configuration to provide a gain of 2.
  • 4-20 mA to 1-10 VDC






Monday, December 30, 2019

Must have tools for an Electronics and Instrumentation Engineer


Hardwares

(1) Digital Multimeter: A 3-1/2  DMM is sufficient for most of the electrical and electronic measurements.

(2) Wires: 0.5, 0.75, 1 sq.mm wires spool are must. One can also use jumper wires.

(3) Screw-driver set

(4) Discrete electrical components (Inductors, Resistors, Capacitors)

(5) Power supplies (variable AC, DC)

(6) Wire cutter

(7) Wire stripper

(8) Insulation tapes

(7) ICs-

  • Operational amplifiers (LM741, OP07, LF356)
  • Timer IC (NE555)
  • Comparator (LM311)
  • Instrumentation amplifier (INA101, AD623)
  • Monoshot (74LS121/74LS123)
  • Digital IC -(AND, OR, NOR, NAND, NOT)

Softwares

(1) Proteus- For PCB designing
https://www.labcenter.com/downloads/

(2) LabVIEW - For data acquisition, processing, User interface design, machine vision,control-system design
https://www.ni.com/en-in/support/downloads/software-products/download.labview.html#329059

(4) Matlab- For mathematical analysis,image processing,control system design
https://www.mathworks.com/campaigns/products/trials.html

NB: Images copied from Google Images

Friday, December 27, 2019

Measuring temperature using Thermistor

  • Thermistor is a semiconductor based (metallic compounds including oxides such as manganese, copper, cobalt and nickel as well as single-crystal semiconductors silicon silicon and germanium) temperature sensor.
  • They are commonly packaged in a thermally conductive glass bead or disk with two metal leads.
  • It is a NTC (negative temperature coefficient) device i.e. its resistance decreases with rise in temperature. Although PTC Thermistors are also available, it is the NTC type which has gained wide attention.
  • When the doping is very heavy, the semiconductor achieves metallic properties and shows a positive temperature coefficient over a limited temperature range.
  • Thermistor is highly non-linear and one of the most sensitive temperature sensor. The high sensitivity of thermistor allows it to detect very small change in temperature which otherwise would not be possible with Themocouple and RTD.

Listed below are the features of Thermistor one need to consider:
(1) Very high sensitivity: It yields higher resolution in temperature measurement
(2) High sensitivity allows use of small mas and thus fast response and low measurement error
(3) Non-linear response
(4) Small geometry allows them to be easily integrate with electronic circuitry

The Resistance-temperature relationship of a Thermistor is governed by the equation

Rt = Ro{exp[B(1/T - 1/To)]}

Rt = Thermistor Resistance at T Kelvin
Ro = Thermistor resistance at To Kelvin
B= Temperature coefficient, ~3000-4000K
The above curve shows characteristics of a Thermistor with resistance 10k at 25 degC.
 
Relative sensitivity of Thermistor is:
 
B can be calculated from the NTC thermistor resistance at two reference temperature T1 and T2

Because of its high sensitivity and large resistance, it is not required to use 4-wire method (Kelvin's Bridge configuration) for Thermistor resistance measurement. A lead wire of 20 Ohm resistance would only cause less than 0.05 deg C error in measurement at 25 deg C which is insignificant for most practical purposes.

Lets do some math to validate above statement.

1/T - 1/To = (1/B)log(Rt/Ro)

dT/dRt = (T*T)/(B*Rt)

dT = 298*298*20/(3500*10000) = 0.05deg C
 
There is also a 3-parameter model of Thermistor given by the following equation known as Steinhart and Hart equation:
 

Linearizing Thermistor response

One disadvantage of using Thermistor is its non-linear behaviour. Its response can be linearized by adding a fixed shunt resistor but linearity comes at the cost of reduced sensitivity. 

The value of the fixed resistor can be calculated from the following equation.
where RT1 is the thermistor resistance at T1, the lowest temperature in the measurement range, RT3 is the thermistor resistance at T3, the highest temperature in the range, and RT2 is the thermistor resistance at T2, the midpoint, T2 = (T1 + T3)/2.
 
Interfacing with Data acquisition system:
 
As most data acquisition systems accept voltage input, it is recommended to convert change in voltage to corresponding change in voltage. A voltage divider network consisting of Thermistor and precision resistor is generally used.The accuracy of reference voltage also affects the accuracy of measurement.
Usually the value of R is taken to be equal to Thermistor resistance @25 degC. To avoid loading, the output voltage is fed to a voltage buffer.

Questions
GATE-2007
GATE-2008
GATE-2009
GATE-2014
A thermistor has a resistance of 1 kΩ at temperature 298 Kand 465 Ω at temperature 316 K. The temperature sensitivity in /K[i.e. (1/R)(dR/dT), where R is the resistance at the temperature T(in K)], of this thermistor at 316 K is ___________.



Friday, September 20, 2019

Understanding the working of Calorimetric flowmeter or Thermal Mass flowmeter


Calorimetric flow meters, as the name implies rely on calorie (heat) measurement. It is also known as thermal mass flow meter. It consists of two temperature sensors (mostly thermistors) and a heating element. One of the sensing element is constantly heated using heating element at constant power. This sensing element measures the temperature of heating element. The other sensing element measures the temperature of the medium in the pipe. The temperature difference is recorded and processed.

When the liquid flows through the pipe, it takes along the heat from tip of the probe, thus reducing tip temperature. Higher the flow velocity, more is the cooling and less is the temperature difference between two sensors.

The sensor heating can be done in two modes-

  1. Continuous heating mode: In this mode the heater is continuously ON because of which one thermistor is always hot and other is cold. The temperature difference which reduces with rise of flow is monitored.
  2. Pulsed or regulated heating mode: In this mode the the heating power is regulated so as to keep the temperature difference between sensors constant. With more flow, heating power required is more. By measuring the power, flow is calculated.

Schematic illustration of a measuring probe for a calorimetric flow switch

The mathematical equation governing the constant power type flowmeter is as below:
where v is the velocity of the medium, K is the calibration constant, p is the density of fluid, Ts is the sensor tip temperature, To is the medium temperature, Q is the heat supplied to heater.

Both temperature detectors (heated and reference sensor) can be connected in a bridge circuit as shown in figure above. At very low flow velocities, the bridge is imbalanced. At very low flow velocities, the bridge is imbalanced and the output signal is high. When the flow rate increases, the heated detector cools down and its temperature comes closer to that of a reference detector, lowering the output voltage.

These type of flowmeters have following characteristics:
(1) Accuracy : +/- 5%,
(2) Can measure both flow and temperature of the medium
(3) Maintenance free
(4) Easy to install. Can be mounted in any position. The sensing probe shall be completely immersed in the medium.
(5) Correction factor is required when used for liquids other than water. This is due to different thermal conductivity (k) values.

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