20 Intelligent Devices

0908341 Measurements & Instrumentation Chapter 20 Intelligent Devices (Revision 1.0, 24/5/2008)

1. Introduction When discussing the types of instruments earlier in this course, we mentioned that one classification is smart and non-smart devices and instruments. The term intelligent is used to describe a package containing either a complete measurement system, or else a component within a measurement system, which incorporates a digital processor. Processing of the output of measurement sensors to correct for errors inherent in the measurement process brings about large improvements in measurement accuracy. Such intelligent devices are known by various names such as intelligent instruments, smart sensors and smart transmitters. The first intelligent instrument appeared around 20 years ago, but the high price limited the increase in use of these instruments. Intelligent Instruments have self contained digital processors that can carry out necessary processing on the signal (such as pre-programmed signal processing and data manipulation algorithms). The drastic reduction in the cost of processors is a factor in the increase of their use nowadays. 2. Correction for environmental disturbances One of the main functions performed by the first intelligent instruments to become available was compensation for environmental disturbances to measurements that cause systematic errors (effect of temperature or humidity on zero drift or sensitivity drift). Thus, apart from the primary sensor to measure the variable of interest, intelligent instruments usually have one or more secondary sensors to monitor the value of environment disturbances. The extra sensor(s) allow automatic correction for the effect of environmental disturbances. This is done as follows: a) The physical mechanism and the variables that could affect the variable that is being measured must be identified; The effect of each of these ambient variables on the output must be quantified. Trying to do this analytical can be very complex and it is usually easier to do this by empirical methods (i.e., changing the environment variable and measuring the output). Suitable secondary sensors for monitoring these values of these disturbing variables must be fitted within the sensor (ensuring that they can function under the expected environment conditions).

b)

c)

Examples of disturbance environmental variables are: a) Temperature.

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20 Intelligent Devices b) c) d) e) Pressure. Humidity. Gravitational force.

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Power supply changes.

3. Application in flow measurement One of the earliest applications of intelligent instrumentation was in the measurement of volume flow rate. The flow rate is inferred by measuring the difference in pressure across an orifice-plate placed in a fluid carrying pipe. The flow rate is proportional to the square root of the difference in pressure across the plate. However, for a given flow rate this relationship is affected both by the temperature and by the mean pressure in the pipe. A typical intelligent flow-meter therefore contains three sensors, a primary one measuring pressure difference across the orifice plate and secondary ones measuring temperature and absolute pressure in the pipe. The instrument is then programmed to correct the output of the primary differential-pressure sensor according to the values measured by the secondary sensors, using appropriate physical laws that quantify the effect of ambient temperature and pressure changes on the fundamental relationship between flow and differential pressure. Even 20 years ago, such an intelligent flow measuring instrument achieved typical inaccuracy levels of 0.1%, compared to 0.5% for their non-intelligent equivalents. 4. Other features of intelligent Instruments Although correcting for environmental disturbances is one of the most important functions of intelligent instruments, they have many other functions. As an example the flow sensor just mentioned can carry out the conversion of the relationship between the flow and the output signal from a square root one to a linear one. Other features are: 1. Self calibration capability: Self calibration is very simple in some cases. A sensor with an electrical output can use a known reference voltage to carry out self-calibration. Also, load-cell types of sensors that are used in weighing systems can adjust the output reading to zero when there is no applied weight. For more complicated calibration, two methods are possible: Look up tables that need to be stored into the unit; or interpolation methods that uses a small matrix of values to apply a correction to any particular measurement. Converting from one relationship between the input and output to another more convenient relationship (e.g., converting the square root relationship between the flow and the signal output to a linear one as discussed above).

2.

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20 Intelligent Devices 3.

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Correction/compensation for the loading measurement system on the measured variable. Signal damping with selectable time constants.

4. 5.

Switchable ranges (using several primary sensors within the instrument, each of which covers a specific range). Adjustment for measurement of non-linearities to produce a linear output: Some instruments can use digital processing to compensate or remove the non-linearity between the input and output. This requires an understanding of the non-linear relationship. The solution can be carried out by using the inverse equation or a lookup table. Self-diagnosis of faults: The instrument is capable of identifying various types of faults and raising an alarm or sending a fault code. The difficulty lies in distinguishing between extreme signal variations and fault conditions. Some intelligent devices overcome this problem by storing a large number of readings around a set-point and calculating minimum and maximum expected values for the measured quantity. Remote adjustment and control of instrument parameters from up to 1500 metres away via 4-way, 20 mA signal lines. Automatic calculation of measurement accuracy and compensation for random errors: Some intelligent instruments can calculate measurement accuracy on line by computing the mean over a number of measurements and analysing all the factors affecting accuracy. This averaging process serves to greatly reduce the magnitude of random measurement errors (Note: one of the methods of removing noise from the signal was averaging).

6.

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8.

9.

5. Miniaturisation and integration Over the years since the development of the first intelligent sensors, the size of intelligent instruments has gradually reduced and the performance has steadily increased. This is in effect a practical demonstration of Moores Law (see Figure 1 below). Moore's Law is the empirical observation made in 1965 that the number of transistors on an integrated circuit for minimum component cost doubles every 24 months. It is attributed to Gordon E. Moore (1929 ), a co-founder of Intel. It was found in practice based on Intel products that 18 months is more correct, and this has held correct from 1971 to 2004

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20 Intelligent Devices

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Figure 1: Moore's Law. Processors are now installed within the sensor itself, leading to what is called smart sensors. These smart sensors are sometimes packaged with other sensors and signal processing circuits within the same unit. Manufacturers sometimes called these intelligent transmitters rather than intelligent instruments. All of the features discussed earlier in this document apply to all three items. References [1] Measurement & Instrumentation Principles, Alan S. Morris, Elsevier, 2001.

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