1、Sensor Selection Guide:Optimizing Manufacturingand Processes2nd EditionChapman2006.book Page i Tuesday, June 13, 2006 10:29 AMChapman2006.book Page ii Tuesday, June 13, 2006 10:29 AMSensor Selection Guide:Optimizing Manufacturingand Processes2nd EditionBy Paul W. ChapmanChapman2006.book Page iii Tue
2、sday, June 13, 2006 10:29 AMNoticeThe information presented in this publication is for the general education of the reader. Because neither the author nor the publisher have any control over the use of the information by the reader, both the author and the publisher disclaim any and all liability of
3、 any kind arising out of such use. The reader is expected to exercise sound professional judgment in using any of the information pre-sented in a particular application.Additionally, neither the author nor the publisher have investigated or considered the affect of any patents on the ability of the
4、reader to use any of the information in a particular application. The reader is responsible for reviewing any possible patents that may affect any particular use of the information presented.Any references to commercial products in the work are cited as examples only. Neither the author nor the publ
5、isher endorse any referenced commercial product. Any trademarks or trade-names referenced belong to the respective owner of the mark or name. Neither the author nor the publisher make any representation regarding the availability of any referenced commercial product at any time. The manufacturers in
6、structions on use of any commercial product must be followed at all times, even if in conflict with the information in this publication.Copyright 2006 by ISAThe Instrumentation, Systems, and Automation Society67 Alexander DriveP.O. Box 12277Research Triangle Park, NC 27709All rights reserved.Printed
7、 in the United States of America.10 9 8 7 6 5 4 3 2 ISBN-13: 978-1-55617-987-7ISBN-10: 1-55617-987-1No part of this work may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior writ-t
8、en permission of the publisher.Library of Congress Cataloging-in-Publication Data Chapman, Paul W.Sensor selection guide : optimizing manufacturing and processes / byPaul W. Chapman. - 2nd ed.p. cm.Rev. ed. of: Smart sensors. 1996.Includes bibliographical references and index.ISBN 1-55617-987-1 (pbk
9、.)1. Engineering instruments-Programmed instruction. 2.Detectors-Programmed instruction. 3. Smart materials-Programmedinstruction. I. Chapman, Paul W. Smart sensors. II. Title. TA165.C43 2006670.42-dc222006017133Chapman2006.book Page iv Tuesday, June 13, 2006 10:29 AMvTable of ContentsPreface . . .
10、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viiUnit 1: Introduction and Overview1-1. Course Coverage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31-2. Purpose . . . . . . . . . . . .
11、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41-3. Audience and Prerequisites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41-4. Study Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41-5. Org
12、anization and Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51-6. Course Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51-7. Course Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13、 . . . . 5Unit 2: Sensors and Sensing: History and Definitions2-1. What Is a Sensor? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92-2. Early Sensor Development . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122-3. Overview of Smart Sensing a
14、nd Control Systems . . . . . . . . . . . . . . 152-4. Sensor Types and Their Typical Use . . . . . . . . . . . . . . . . . . . . . . . . . 16Unit 3: Sensor Technologies3-1. Todays Sensor Technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233-2. Digital and Analog Sensors: App
15、lication Examples . . . . . . . . . . . . 42Unit 4: Sensor Manufacturing4-1. Silicon-based Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494-2. Silicon-based Sensor Manufacturing . . . . . . . . . . . . . . . . . . . . . . . . . 51Unit 5: Smart Sensing: “Adding
16、Value” to the Sensing Circuit5-1. Smart Sensors? Smart Sensing? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615-2. Do Requirements for Sensor “Smartness” Exist Only at the Higher Levels of Sophistication? . . . . . . . . . . . . . . . . . . . . . . . 645-3. Environmental Compensation
17、 in Silicon Integrated-CircuitTechnology as Applied to Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . 665-4. Advances in Communication Abilities: Making theSensor Smarter by Improving Its Ability to Communicate with the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18、. 735-5. Self-Diagnostics: Enhancing Sensor Functionality by Making It Able to Anticipate Function Problems . . . . . . . . . . . . . . 74Unit 6: Control Partitioning: Should the “Smarts” Be in the Sensor or the System?6-1. Why Is Control Partitioning Important to the Sensor User? . . . . . 816-2. D
19、eciding Which Capabilities Should Reside in the Sensor and Which in the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 826-3. Requirements for Smart Sensing in Broad Markets . . . . . . . . . . . . . 86Unit 7: Sensors + Artificial Intelligence: The “High End” of Sensor Partitioning7-
20、1. Artificial Intelligence: What Is It? . . . . . . . . . . . . . . . . . . . . . . . . . . . . 937-2. Monitoring Intangible Parameters Using an Artificial Intelligence Sensing Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 957-3. How to Create an AI Sensing Network . . . . .
21、. . . . . . . . . . . . . . . . . . 977-4. Advantages of Using AI Combined with Sensing . . . . . . . . . . . . . 100Chapman2006.book Page v Tuesday, June 13, 2006 10:29 AMvi Table of Contents7-5. Challenges to Widespread Development and Use of AI Sensing Networks . . . . . . . . . . . . . . . . . .
22、 . . . . . . . . . . . . . . . . . . . 100Unit 8: Sensor Packaging: Pulling It All Together8-1. What Is Sensor Packaging? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1058-2. What Should an Effective Sensor Package Do? . . . . . . . . . . . . . . . 1078-3. Sensor Packaging at Two
23、Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1078-4. Sensor Packaging in Various Markets . . . . . . . . . . . . . . . . . . . . . . . 1148-5. Sensor Packaging Attributes Important to All Markets . . . . . . . . 1178-6. Trends in Packaging Standards . . . . . . . . . . . . . . . .
24、. . . . . . . . . . . . 117Unit 9: Bus-based Sensing Systems: Combining Controls, Communication, and Diagnostic Capabilities9-1. What Is a Bus-based Sensing System? . . . . . . . . . . . . . . . . . . . . . . . 1239-2. Distributed Machine Control . . . . . . . . . . . . . . . . . . . . . . . . . . .
25、 . . . 1249-3. Overall Benefits of Bus-based Sensing Systems . . . . . . . . . . . . . . . 130Unit 10: Is There Life after Silicon? (a.k.a.: The Future of Sensors)10-1. Other Sensor Types Currently in Development . . . . . . . . . . . . . . . 13510-2. Where to from Here? . . . . . . . . . . . . . .
26、. . . . . . . . . . . . . . . . . . . . . . . 145Appendix A: Sensor Application Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147Appendix B: Suggested Readings and Study Materials. . . . . . . . . . . . . . . . . . . . . 153Appendix C: Solutions to All Exercises . . . . . . .
27、. . . . . . . . . . . . . . . . . . . . . . . . . . . 169Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175Chapman2006.book Page vi Tuesday, June 13, 2006 10:29 AMviiPREFACEISAs Independent Learning ModulesThis book
28、 is an Independent Learning Module (ILM) as developed and published by ISA. The ILMs are the principal components of a major educational system designed primarily for independent self-study. This comprehensive learning system has been custom designed and created for ISA to more fully educate people
29、in the basic theories and technologies associated with applied instrumentation and control.Paul W. MurrillConsulting Editor, ILM SeriesComments About This VolumeBooks on the application of sensors generally fall into one of two categories based either on sensing applications or what needs to be sens
30、ed (i.e., temperature, flow, position, etc.) or on the devices that sense these parameters (i.e., proximity sensors, photoelectric controls, microstructure sensors, etc.). In order to develop a real understanding of smart sensing, however, it is useful to view the topic from the perspective of both
31、of these areas. That is what this book attempts to do. This book also contains information concerning how choices could be made as to what sensor technology needs to be used for what specific applications. Its extremely important to understand that these choices need to be made because there are a l
32、arge variety of sensor technologies available, oftentimes overlapping particular applications.This broad conceptual framework will allow the practicing professional or the beginning student to develop an appreciation of the tools that are available for creating solutions to sensing problems.This boo
33、k presents no new research, nor does it advocate any pet ideas. Its sole purpose is to promote understanding.AcknowledgmentsThe author gratefully acknowledges the help of personnel employed by the MICRO SWITCH Division of Honeywell, Ramon A. Alvarez, Vice President and General Manager.Special thanks
34、 to Marilyn E. Smit, Director of Marketing Communications, for her overall editing, and to Marilyn Picking, Leslie Mantua, and Wendy Gustafson for help with the figures.Chapman2006.book Page vii Tuesday, June 13, 2006 10:29 AMviii PrefaceAlso, the author would like to acknowledge the help of personn
35、el employed by the Finisar Corporation, Jerry S. Rawls CEO and Chairman of the Board, as well as Kerry A. Craven for specific technical editing, Susan Morrill for manuscript preparation, and Dr. Jim Tatum for additional figure preparation.Chapman2006.book Page viii Tuesday, June 13, 2006 10:29 AMUni
36、t 1:Introduction andOverviewChapman2006.book Page 1 Tuesday, June 13, 2006 10:29 AMChapman2006.book Page 2 Tuesday, June 13, 2006 10:29 AM3UNIT 1 Introduction and OverviewThis is an ISA Independent Learning Module entitled Sensor Selection Guide: Optimizing Manufacturing and Processes, 2nd Edition.
37、This unit provides an overview of the course and the information you will need for independent study.Learning ObjectivesWhen you have completed this unit you should:A. Know the nature of the material in the course.B. Understand the general organization of the material.C. Know the course objectives.1
38、-1. Course CoverageThis course outlines the concept of sensing and smart sensing, as well as the many facets of sensor applications. The course covers: What sensors are and some simple descriptions of how they are designed How sensors work The strengths and limitations of various types of sensors Ho
39、w sensors function within control systems (their applications) Why it is important to add intelligence to sensor technology and sensor packages today How to determine which sensor technologies are most appropriate for which sensing applicationsIn addition, how a sensor interfaces with the control sy
40、stem in which it operates (“sensing subsystems”) and how to ensure that the selected interface is most effective for the overall system will be reviewed. The importance of the role that sensor packaging plays in developing the appropriate sensor for a specific application is highlighted, and the fut
41、ure of sensor technology and how the intelligence embedded within the sensor will become more important as new markets are defined for these devices are discussed.Chapman2006.book Page 3 Tuesday, June 13, 2006 10:29 AM4 UNIT 1: Introduction and OverviewThis text will not cover first principle deriva
42、tions of the interaction of various external stimuli with the sensor material.1-2. PurposeThe purpose of this ILM is to present in easily understood terms the basic concepts of sensing, smart sensing, and sensing systems and to illustrate each of these concepts. This ILM will also provide informatio
43、n concerning the selection process with respect to which sensors are best suited for which sensor applications. This is neither solely a theoretical course nor solely a practical course; it is both.The purpose is to show the theoretical concepts of sensing in day-to-day commercial and industrial sit
44、uations and, in doing so, to show how this theory is quite practical.1-3. Audience and PrerequisitesThis ILM is designed for those who want to work on their own and who want to gain a basic introductory understanding of sensing, sensor applications, and smart sensing within the context of an overall
45、 control system. The material will be useful to engineers, first-line supervisors, and technicians who are concerned with sensors or system design. The course will also be helpful to students in technical schools, colleges, or universities who wish to gain some insight into these important concepts.
46、No elaborate prerequisites are required to take this course, although an appreciation for industrial and commercial equipment, concerns, and philosophies will be helpful. In addition, it is inevitable that some mathematics, physics, and general science will be involved in particular parts of the pre
47、sentation. It is not necessary for the student to be intimately familiar with such subjects in order to appreciate the concepts that will be presented and applied, and lack of extensive knowledge in these subjects should not be perceived as a barrier to successfully completing this ILM.1-4. Study Ma
48、terialThis textbook is the only study material required in this course; it is one of ISAs ILM System. It is an independent, stand-alone book that is uniquely and specifically designed for self-study.Appendix B provides a list of additional references and study materials for the student. The student
49、also will find it most helpful to study the other ILMs that are available from ISA, which present a broad range of specific applications of instrumentation and control. Chapman2006.book Page 4 Tuesday, June 13, 2006 10:29 AMUNIT 1: Introduction and Overview 51-5. Organization and SequenceThis ILM is divided into ten units. Units 1 and 2 outline sensor history and define terms. Units 3 to 7 discuss initial and current smart sensing activity, with examples. Unit 8 focuses on the important area of sensor packaging. Units 9 and 10 discuss various sensor subsystems, sensor mat
