ISA FUND TST MEAS INSTA-2006 Fundamentals of Test Measurement Instrumentation.pdf

1、Fundamentals ofTest MeasurementInstrumentationCheatle-2006.book Page i Monday, February 20, 2006 11:05 AMCheatle-2006.book Page ii Monday, February 20, 2006 11:05 AMFundamentals ofTest MeasurementInstrumentationby Keith R. CheatleCheatle-2006.book Page iii Monday, February 20, 2006 11:05 AMCopyright

2、 2006 by ISA Instrumentation, Systems, and Automation Society67 Alexander DriveP.O. Box 12277Research Triangle Park, NC 27709All rights reserved.Printed in the United States of America.1098765432ISBN-13: 978-1-55617-914-3ISBN-10: 1-55617-914-6No part of this work may be reproduced, stored in a retri

3、eval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of the publisher.NoticeThe information presented in this publication is for the general education of the reader. Because neither the author nor

4、the publisher has any control over the use of the information by the reader, both the author and the publisher disclaim any and all liability of any kind arising out of such use. The reader is expected to exercise sound professional judgment in using any of the information presented in a particular

5、application. Additionally, neither the author nor the publisher have investigated or considered the effect of any patents on the ability of the reader to use any of the information in a particular application. The reader is responsible for reviewing any possible patents that may affect any particula

6、r use of the information presented. Any references to commercial products in the work are cited as examples only. Neither the author nor the publisher endorses any referenced commercial product. Any trademarks or tradenames referenced belong to the respective owner of the mark or name. Neither the a

7、uthor nor the publisher makes any representation regarding the availability of any referenced commercial product at any time. The manufacturers instructions on use of any commercial product must be followed at all times, even if in conflict with the information in this publication.Library of Congres

8、s Cataloging-in-Publication DataCheatle, Keith.Fundamentals of test measurement instrumentation / by Keith Cheatle.p. cm.Includes index.ISBN 1-55617-914-6 (pbk.)1. Electronic instruments. 2. Testing-Equipment and supplies. 3.Physical measurements. I. Title. TK7878.4.C43 2006620.0044-dc222006000524Ch

9、eatle-2006.book Page iv Monday, February 20, 2006 11:05 AMAcknowledgmentsThe creation of this book has been a rewarding experience that was made easier through the efforts of a number of others.I would like to acknowledge the encouragement and support of my wife, Barb, who has been steadfastly behin

10、d the project from the start. Her efforts to share knowledge of her own chosen profession were an inspiration to me.Our two Shi Tzus, Cricket and Misty, provided many hours of company sleeping below the computer desk while I hit the keyboard above.I would also like to acknowledge the helpful comment

11、s of the reviewer that certainly improved the content of the book.Finally I would like to acknowledge the work of the ISA editorial staff whose expert advice made the book much easier to read.Cheatle-2006.book Page v Monday, February 20, 2006 11:05 AMCheatle-2006.book Page vi Monday, February 20, 20

12、06 11:05 AMviiAbout theAuthorKeith R. Cheatle is a Professional Engineer registered in the Provinceof Ontario, Canada. He holds a Bachelors degree from Ryerson Poly-technical Institute (now Ryerson University) in Toronto. He joined ISAin 1965 as a student member, became a member in 1966, a senior me

13、m-ber in 1982, and a life member in 1998.Mr. Cheatle worked for over 37 years in the Instrumentation Section ofAtomic Energy of Canada Limited and was Section Head for 25 years.This section provided test instrumentation systems for use in a devel-opment laboratory environment. It tested components a

14、nd systemsthat were to be used in nuclear power stations. The section was alsoresponsible for the process instrumentation used on the high pressure,high temperature circulating water test loops used to simulate nuclearreactor operating conditions.In addition, the Instrumentation Section operated a s

15、tate-of-the-art cal-ibration laboratory for in-house calibration of instrumentation systemsunder an ISO 9001 quality assurance program. Mr. Cheatle wasresponsible for the design and operation of this calibration facility.As the Section Head, Mr. Cheatle trained technicians and junior engi-neers in t

16、he application of test instrumentation. This training consistedof both lectures and on-the-job instruction.Cheatle-2006.book Page vii Monday, February 20, 2006 11:05 AMCheatle-2006.book Page viii Monday, February 20, 2006 11:05 AMixTable ofContentsAbout the Author . . . . . . . . . . . . . . . . . .

17、 . . . . . . . . . . . . . . . . . . . . . . . . . . .viiForeword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xv1 Introduction to Test Measurement Instrumentation. . . . . . . . . . . . . . .11.1 Introduction 11.2 Why and Where Test Measuremen

18、t Instrumentation Is Used 21.3 Components of a Test Measurement System 31.4 Characteristics of an Ideal Test Measurement System 101.5 Differences between Test Measurement Instrumentation and Process Instrumentation 141.6 Smart Transducers 162 Static Transducer Characteristics . . . . . . . . . . . .

19、 . . . . . . . . . . . . . . . .192.1 Hysteresis 262.2 Deadband 292.3 Linearity 322.4 Conformity 392.5 Repeatability 392.6 Accuracy 412.7 Resolution 422.8 Environmental Effects on Transducer Characteristics 43Cheatle-2006.book Page ix Monday, February 20, 2006 11:05 AMx Fundamentals of Test Measurem

20、ent Instrumentation3 Dynamic Transducer Characteristics . . . . . . . . . . . . . . . . . . . . . . . . .453.1 Frequency Response 473.2 Response Time 493.3 Damping 504 Transducer Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .534.1 Temperature Transducers 534.

21、2 Pressure Transducers 674.3 Flow Transducers 774.4 Displacement Transducers 894.5 Velocity Transducers 994.6 Acceleration Transducers 1004.7 Force Transducers 1054.8 Strain Transducers 1085 Signal Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1175.1 Volta

22、ge Amplifiers 1195.2 Linearizing Amplifiers 1225.3 Strain Gauge Amplifiers 1235.4 Charge Amplifiers 1265.5 Filters 1285.6 Signal Isolators 1295.7 Analog-to-Digital Converters 1305.8 Differential versus Single-Ended Inputs 1316 Transducer Installation . . . . . . . . . . . . . . . . . . . . . . . . .

23、 . . . . . . . . . . .1356.1 Wiring and Cabling 1366.2 Grounding 1386.3 Connecting to the Test Rig 1387 Data Acquisition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1437.1 Digital Indicators 1437.2 Recorders 1467.3 Data Loggers 1467.4 Data Acquisition Systems 14

24、77.5 Filters 151Cheatle-2006.book Page x Monday, February 20, 2006 11:05 AMTable of Contents xi8 Data Reduction and Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1538.1 Graphing 1548.2 Sorting 1558.3 Signal Analyzers 1569 Equipment Calibration. . . . . . . . . . . . . . . . .

25、 . . . . . . . . . . . . . . . . . . . .1599.1 Component Calibration 1659.2 System Calibration 1669.3 In Situ Calibration 1669.4 Calibration Standards 1679.5 Multifunction Calibrators 1689.6 Calibration Records 1699.7 Calibration Laboratory Requirements 1719.8 Calibration System Software 1729.9 Soft

26、ware Validation 1749.10 Quality Assurance System Requirements 1759.11 International, National, and Other Standards 1769.12 Calibration Equipment Specifications 17810 Pressure Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18310.1 Dead-Weight Testers 18310.2 Wa

27、ter Dead-Weight Testers 18910.3 Oil Dead-Weight Testers 19010.4 Pneumatic Dead-Weight Testers 19010.5 Digital Calibrators 19110.6 Manometers 19311 Temperature Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19711.1 Temperature Calibration Baths 19811.2 Dry Block Cali

28、brators 20311.3 Temperature Calibration Furnaces 20411.4 Infrared Calibrators 20511.5 Thermocouple and RTD Simulators 20611.6 Standard Platinum Resistance Thermometers 20811.7 Triple Point of Water Cells 21011.8 Metal Fixed Point Cells 21211.9 Ice Baths 21411.10 Boiling Point of Water 215Cheatle-200

29、6.book Page xi Monday, February 20, 2006 11:05 AMxii Fundamentals of Test Measurement Instrumentation12 Electrical Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21712.1 Voltage 21712.2 Current 21912.3 Resistance 22012.4 Thermocouples 22212.5 Multifunction Cal

30、ibrators 22313 Force Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22713.1 Dead-Weight Force Calibration 22713.2 Proving Rings 23313.3 Hydraulic Presses 23413.4 Shunt Calibration 23514 Flow Calibration . . . . . . . . . . . . . . . . . . . . . . . . . .

31、 . . . . . . . . . . . . . . . .23914.1 Provers 24114.2 Weigh Tank 24314.3 PVTt Calibration Facility 24514.4 Reference Flow Sensor 24615 Displacement Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24915.1 Gauge Blocks 25015.2 Dial Indicators 25116 Vibration Calibratio

32、n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25316.1 Shaker Table 26016.2 Reference Accelerometer 26217 Strain Gauge Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26317.1 Bridge Shunt Calibration 26418 System Accuracy . . . . . . . .

33、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26918.1 System Accuracy Statistics 27018.2 Root Sum Square Versus Sum of Errors 27518.3 Standards Accuracy 27718.4 Test Uncertainty Ratio 27818.5 Uncertainty Versus Accuracy 279Cheatle-2006.book Page xii Monday, February 20, 2006 11:05

34、 AMTable of Contents xiii19 Transducer Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28519.1 Interpreting Manufacturers Specification Sheets 28619.2 Transducer Type 29719.3 Operating Principle 29819.4 Accuracy (% of full scale vs. % of reading) 29819.5 Linearity 299

35、19.6 Hysteresis 30019.7 Environmental Operating Limits 30020 Test Procedure Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30320.1 Test Objective 30420.2 Required Measurements 30420.3 Accuracy Requirements 30420.4 Frequency Response Requirements 30520.5 Transducer Test

36、 Environment Limits 30620.6 Transducer Connections and Space Limitations 30620.7 Test Data Format 30720.8 Test Data Analysis 30820.9 Transducer Selection 30920.10 Calibration Requirements 309Appendix 1Internet Links to Measurement Instrumentation Information. . . . .311Appendix 2Internet Links to Ge

37、neral Engineering Information. . . . . . . . . . . . .323Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325Cheatle-2006.book Page xiii Monday, February 20, 2006 11:05 AMCheatle-2006.book Page xiv Monday, February 20, 2006 11:05 AMxvFo

38、rewordThis book introduces you to the exciting world of test measurementinstrumentation. Extensive coverage is provided about the transduc-ers, signal conditioning, data acquisition, and data analysis equipmentused to make typical measurements. These measurements are rou-tinely made in research and

39、development laboratories, product devel-opment laboratories, and manufacturing facilities. The automotiveindustry and the consumer electronics industry are including moreand more measurement systems in order to improve their products.You are informed about how the separate components mentionedabove

40、are combined to form a measurement system and about theadvantages and disadvantages of the various transducer types. Thedescription of static and dynamic characteristics of transducers leadsyou into an understanding of the factors that affect the accuracy of thesystem and into the concept of measure

41、ment uncertainty. Detailedinformation about the calibration of measurement systems and theequipment used to carry out calibrations is a major part of the book. Acomprehensive listing of Internet links to further test measurementinformation and links to related general engineering information isprovi

42、ded in appendices.With a few exceptions, the subject of measurement instrumentation isnot taught as part of technician and engineering curriculums in col-leges and universities. Knowledge of the subject is typically gainedthrough years of on-the-job experience and attendance at coursesCheatle-2006.b

43、ook Page xv Monday, February 20, 2006 11:05 AMxvi Fundamentals of Test Measurement Instrumentationdesigned to gain knowledge of specific equipment or individual partsof the wide-ranging subject. The book strives to provide the basicinformation required to start making meaningful measurements andhope

44、fully minimize the mistakes that can be made by improper appli-cation of the equipment.Working in the field of test measurement instrumentation is both chal-lenging and rewarding. One is able to work with leading-edge tech-nology and able to apply knowledge of many engineering disciplines.The work i

45、s constantly changing and constantly requiring the practi-tioner to learn new theoretical and practical information. I hope thatthe contents of this book will inspire you to join the ranks of the mea-surement instrumentation professionals.Keith R. Cheatle, P.Eng.Cheatle-2006.book Page xvi Monday, Fe

46、bruary 20, 2006 11:05 AM11Introduction to TestMeasurementInstrumentation“I often say that when you can measure what you are speaking about, andexpress it in numbers, you know something about it, but when you cannotexpress it in numbers, your knowledge is of a meagre and unsatisfactory kind;it may be

47、 the beginning of knowledge, but you have scarcely, in yourthoughts, advanced to the stage of Science, whatever the matter may be.” Sir William Thompson, Lord Kelvin (18271907)1.1 IntroductionThe opening quotation, by Lord Kelvin, shows the importance ofbeing able to measure parameters and record or

48、 display the resultingmeasurements in numbers. Measurements allow us to make specificconclusions about the physical conditions of a test object and abouthow the object responds to changes in its environment. These mea-surements allow us to verify that the object will perform correctlyunder the speci

49、fied conditions and verify that future changes to theobject do not affect its performance. The quotation also underscoresthe important role that measurements play in advancing scientificknowledge.This book introduces students, technicians, technologists, and engi-neers to the specialized test instrumentation that is used in Rthe pointer and dial form the display or readout. An example of a slightly more complex test measurement system is adigital pressure gauge. In this case, the sensing element, such as a dia-Cheatle-2006.book Page 3 Monday, February 20, 2006 11:05 AM4 Fundamental