4th and final course in the Embedding Sensors and Motors Specialization.

Instructors: Jay Mendelson, MSME, Lecturer​ & James Zweighaft, MSME

Prior knowledge needed: ECEA 5340 Sensors and Sensor Circuit Design, ECEA 5341 Motors and Motor Control Circuits and ECEA 5342 Pressure, Force, Motion, and Humidity Sensors.

Learning Outcomes

  • Understand how sensor manufacturers characterize and calibrate their sensors.
  • Tune a PID control loop and access the PID control function of the Cypress PSoC development kit for a motor control application.
  • Understand the manufacturing methods used to build electro-mechanical and micro-machined sensors.

Syllabus

Duration: 13 hours

In module 1 you will learn how companies perform process control in their factories. First, you will review how 2nd order transfer functions work, which is the theoretical basis for much of process control. Then you will learn how plant-wide control systems are implemented and details about the software protocols used to communicate between plant controllers and sensors. Then you will perform a lab for PID control with your PSoC system, which will get you some hands-on experience with this type of control system.

Duration: 10 hours

In module 2 you will learn how sensor software is adjusted for optimal performance in the field. First, you will review how non-linear sensor response curves are linearized for more predictable performance. Then you will learn how sensor output is automatically adjusted to account for wide ranges of ambient temperature. Next, you will review how sensors are calibrated, and the certification procedures that companies follow to demonstrate calibration capability. Afterward, you will study how linearization, compensation, and calibration play into sensor accuracy specs. Finally, you will perform a lab for closed loop motor control with your PSoC system, which will get you some hands-on experience with closed-loop systems.

Duration: 9 hours

In module 3 you will first learn how radar level transmitters work, and how they are used to provide accurate readings in all types of process tank conditions. Then you will learn about components and design issues for LIDAR systems used in self-driving vehicles. Afterward, we will teach you about how sensors are customized for medical applications. This includes pressure and temperature sensors that are implanted during surgical procedures, as well as pressure and flow sensors used in patient care equipment.

Duration: 10 hours

In module 4 you will learn how sensors are manufactured. First, you will learn how MEMS construction is used to make miniature flow, pressure, and temperature sensors. Afterward, we will teach you how micro-electronic connections attach the MEMS sensors to connections within plastic encapsulated chips. Then we will discuss how sensor chips are enclosed within sensor housings, and how different designs of housings are used for different applications. Then you will learn how sensors are tested for high reliability in the field.

Duration: 13 hours

This module contains the materials you need to complete the PID Control and Closed-Loop DC Motor control lab assignments.

Duration: 2 hours

Final exam for this course.

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Grading

Assignment
Percentage of Grade

Homework Assignment for Week 1: Process Control

10%

Week 1: Quiz 

4%

Homework Assignment for Week 2: Sensor Characterization

10%

Week 2 Quiz

4%

Homework Assignment for Week 3: Advanced Sensors

10%

Week 2 Quiz

2%

Homework Assignment for Week 4: Sensor Manufacturing

10%

Week 4 Quiz

2%

PID Lab Exam

4%

ECEA 5343 Sensor Manufacturing and Process Control Final Exam

40%

Letter Grade Rubric

Letter Grade 
Minimum Percentage

A

90%

B

80%

C

70%

D

60%

F

50%

Component List

You will need to buy the following components to do the course project based on the videos in this module. Note that if you have already purchased the PSOC 5LP PROTOTYPING KIT, or the STANDARD MOTOR 11605 RPM 5VDC you do not need to buy it again. These parts may be purchased off the Digikey website at www.digikey.com. Or, you may obtain the specs from the site, and purchase them elsewhere.

These are the part numbers for the below table, the lab on Closed Loop Motor Control. You can copy and paste them into the search engine on the Digikey website. You need one of each except for the capacitor (CAP ALUM 4.7UF 10% 25V RADIAL), for which you would need 2.

  • 428-3390-ND (PSOC 5LP PROTOTYPING KIT)
  • P14355-ND (STANDARD MOTOR 11605 RPM 5VDC)
  • 493-15371-ND (CAP ALUM 4.7UF 10% 25V RADIAL)