mobile | classic
Dataweek Electronics & Communications Technology Magazine





Follow us on:
Follow us on Facebook Share via Twitter Share via LinkedIn


Search...

Electronics Buyers' Guide

Electronics Manufacturing & Production Handbook 2017


 

EBV co-develops industrial pressure sensor
22 February 2012, Test & Measurement

Take a pressure sensor, manufactured in millions of pieces each year for automotive applications, add a special 4/20 mA interface for industrial applications and you have a new pressure sensor that, despite its high quality and superb technical data, is most cost effective. This ‘recipe’ summarises EBV Elektronik’s procedure in defining and developing its latest product, Titan, as part of its ‘EBVchips’ initiative.

Having received many, repeated requests from customers through EBV’s FAEs for cost efficient but very precise, high-quality pressure sensors, the company’s internal search for a solution started. In the Dutch-American company Sensata Technologies, EBV finally found the perfect partner to accomplish the Titan project.

Sensata produces 75 million pressure sensors in this capacitive ceramic technology per year for the automotive industry. Although these sensors fulfil the stringent automotive quality criteria, they all have a ratiometric 0/5 V output. However, since a 4/20 mA output is the industry’s usual standard, the sensors without the current interface were only suited for very dedicated industrial applications.

Ceramic as a base

Since 1985 Sensata has manufactured pressure sensors based on its ceramic technology. In an automobile these sensors are used in many different places – a pressure sensor for the air conditioning’s compressor loop being the first application. Sensata holds a market share of over 80% in this application. Enhanced versions of this ceramic-based pressure sensor are present in automatic gear boxes, fuel applications for low-pressure systems (diesel) or for measuring oil pressure. Based on this technology Sensata manufactures pressure sensors that work from low pressure up to 80 bar.

Titan’s ceramic sensing element
Titan’s ceramic sensing element

The sensor’s basis element comprises a ceramic substrate with about 3 mm thickness and a thin, flexible ceramic membrane with thickness of about 0,6 to 1,2 mm. The ceramic membrane is attached to the ceramic substrate in a highly defined distance using a glass bonding process. Regarding their assembly, sensors with different pressure ranges differ through membranes with different thickness as well as electronic calibration. On both ceramic parts there is a thin gold layer that is connected to the electronics via contact leads. Both gold layers form a capacitor with its capacity changing as a function of pressure applied to the membrane; the capacitor’s value is in the 15 pF range.

Using a proprietary charging/discharging process, Sensata evaluates the change of capacity relative to a reference capacitor to generate an output voltage between 0 and 5 V. This system has been developed over many product generations to improve calibration and temperature stability while maintaining the same basic process.

Signal conditioning module
Signal conditioning module

Each single sensor is calibrated at room temperature. As part of the production process they are validated at 23°C and 135°C. In the upper and lower pressure ranges, a calibration is also conducted. All these measures are purely analog without using digital electronics. In manufacturing as well as in the field this process has proven to be extremely stable: within a core range the sensor elements show rather linear characteristics. Only at the lower and upper end of the scale are there larger non-linearities.

EBVchip Titan provides 4/20 mA output

So that the sensors can be used in industrial applications they need a 4/20 mA output. On the initiative of EBV Elektronik the Titan pressure sensors equipped with an industrial output interface were created. EBV together with Sensata defined a backend electronic circuit for converting the 0/5 V signal into a 4/20 mA output current. EBV was responsible for the entire definition of the industrial interface. As a result the sensors can also be used in process automation systems and other applications.

The Titan pressure sensor
The Titan pressure sensor

Many options

Currently the EBVchips pressure sensors are available in brass versions for the three pressure ranges 0–10 bar, 0–20 bar and 0–35 bar. Also available are variants in stainless steel for the 0–45 bar range. If required and the appropriate volume is needed, EBV and Sensata are able to produce other variants equipped with different connectors, different mechanical connection or packaging. At present the sensors are classified according to IP65, IP67 and IP6K9 (all with cable).

Because the sensor is powered via the signal line, the Titan sensors only use two connection lines according to SAE specifications having the relevant length for usage in harsh industrial environments where EMC is an issue. The industrial pressure sensors are immune to electrical interferences of up to 30 V/m.

Across the temperature range of -20°C – +100°C the measurement error is less than 2%. At 25°C the measurement error across the entire pressure range is only 0,75%; this applies for more than 10 million specified pressure measuring cycles. Therefore the sensors are among the most accurate parts on the market. The reverse polarity protected sensor’s operating voltage can be 6-30 V d.c. They can also handle voltages up to 39 V d.c. without damage.

Vibrations up to 10 G with a frequency of 25–2000 Hz do not harm the pressure sensors. They can withstand shocks of 100 G coming from various directions with 6 Hz (half sine). In all cases the UL and RoHS-compliant, CE certified sensors make their measurement result reliably available after a response time of <10 ms via the cost-efficient but IP6K9 protected Delphi-Packard connector on the output. As sealing material for the internal O-ring, Sensata uses neoprene, hydrated nitrile rubber (HNBR) and fluorosilicone. The bursting pressure corresponds to the five-fold measurement pressure.

Using a hexagonal screw terminal (1/8” male, ¼” female) the pressure sensors are not only suited for industrial process automation applications but also for applications like pumps and compressors as well as HVAC (heating, ventilation and air conditioning) plus fridges and freezers. In the area of process automation for example there are important applications in the fields of hydraulic systems, pneumatics, lifts, liquids and gases.

Some of the most important pump and compressor applications are industrial cleaning systems, (car) washing systems, water-based high-pressure cleaners, water and auxiliary pumps as well as pneumatic systems. The HVAC and fridges and freezers sector not only includes industrial freezing technology but also building automation, heat pumps as well as fridges and freezers for food and retail.

From cars to consumer and industrial

Since the end of 2011 new cars sold in the EU must be equipped with an ESP system for driving stability. Core elements of each ESP are two sensors – an angular rate sensor and an acceleration sensor. In the mid-1990s the first ESP systems were put on the market, but only in premium cars. The reason was that at the time the sensors were difficult to produce and very expensive.

Shortly after the legendary moose test in 1997 all of a sudden ESP systems were available down to the compact class. ESP’s commercial success started with using high-quality and relatively cheap to produce silicon-based angular rate sensors and acceleration sensors. Today, inexpensive angular rate sensors and acceleration sensors (MEMS-based) can be found in virtually every new smartphone and in most of the game consoles, with prices for those sensor types falling dramatically due to mass production for cars. At the same time there were no significant quality problems with those consumer sensors because the automotive suppliers had already assured a very high base quality in manufacturing.

Similarly, as part of its EBVchips initiative, EBV has taken an automotive pressure sensor, adapted it to the industry’s requirements and equipped it with the suited 4/20 mA interface. Because those pressure sensors have enjoyed mass deployment in vehicles for many years, the pressure sensor vendor has quality under control. Industrial customers can look forward to double digit price advantages due to high-volume production.

For more information contact EBV Electrolink, +27 (0)21 402 1940, capetown@ebv.com, www.ebv.com


Credit(s)
Supplied By: EBV Electrolink
Tel: +27 11 236 1900
Fax: +27 11 236 1913
Email: saro.murabito@ebv.com
www: www.ebv.com
  Share on Facebook Share via Twitter Share via LinkedIn    

Further reading:

  • Connectivity and reliable power – the keys to Africa’s 4th Industrial Revolution
    18 April 2018, Forbatt SA, Power Electronics / Power Management, Test & Measurement
    Our opportunities in the 4th Industrial Revolution are dead in the water without reliable and portable power.
  • Time-of-flight sensor
    18 April 2018, EBV Electrolink, Analogue, Mixed Signal, LSI
    The VL53L1X time-of-flight sensor from STMicroelectronics extends the detection range of its FlightSense technology to 4 metres, bringing high-accuracy, low-power distance measurement and proximity detection ...
  • Cloud connected last-mile test solution
    21 March 2018, Concilium Technologies, Test & Measurement
    Viavi Solutions has introduced the Mobile Tech application to further enhance the connectivity of its OneExpert family of instruments. Leveraging the always-on connectivity of Android/iOS mobile devices ...
  • Fibre-optic connector inspector with Wi-Fi
    21 March 2018, Comtest, Test & Measurement
    The FOCIS Wi-Fi2 is AFL’s new fibre-optic connector inspection system that uses an Android or iOS wireless connection for live image video streaming, auto-focus and more.    The probe is ergonomic and ...
  • Multi-standard wireless MCUs
    21 March 2018, EBV Electrolink, Telecoms, Datacoms, Wireless, DSP, Micros & Memory
    To meet growing connectivity needs for buildings, factories and the grid, Texas Instruments introduced new SimpleLink wireless microcontrollers (MCUs) offering low power consumption and concurrent multi-standard ...
  • RF digital wattmeter
    21 March 2018, Daytronik Solutions, Test & Measurement
    Telewave’s Model 44D RF digital wattmeter represents the latest generation of the company’s technology, addressing the more demanding requirements associated with digital modulations and protocols. The ...
  • Digital sampling oscilloscope
    21 March 2018, Comtest, Test & Measurement
    On offer from Comtest is the latest Tektronix DSA8300 digital sampling oscilloscope, with intrinsic jitter of less than 100 femtoseconds, providing comprehensive support for optical communications standards, ...
  • Pocket-sized 20 MHz oscilloscope
    21 March 2018, RS Components (SA), Test & Measurement
    The new RS Pro 2205A-20 is an ultra-compact oscilloscope that has a footprint approximately the size of a passport with a thickness of just 19 mm. Connected and powered via USB, it offers a bandwidth ...
  • Testing the versatile USB Type-C interface
    21 February 2018, Concilium Technologies, Test & Measurement
    Keysight Technologies’ Erik Babbé details testing procedures for the versatile but challenging USB Type-C interface.
  • BLE and energy harvesting development boards
    21 February 2018, EBV Electrolink, Computer/Embedded Technology
    ON Semiconductor has released two new boards, or shields, further extending its recently launched Internet of Things (IoT) Development Kit (IDK) platform’s capabilities. With the addition of two new shields ...
  • Microcontrollers for power control
    21 February 2018, EBV Electrolink, DSP, Micros & Memory
    Texas Instruments unveiled its newest additions to the C2000 Piccolo microcontroller (MCU) portfolio. With streamlined performance, the new C2000 F28004x MCU family is optimised for power control in cost-sensitive ...
  • NFC sensor for temperature logging
    21 February 2018, EBV Electrolink, Telecoms, Datacoms, Wireless
    New from ams is the AS39513, an NFC sensor tag and data logger IC for smart labels which enables more efficient and accurate monitoring of the condition of assets such as food, pharmaceuticals and healthcare ...

 
 
         
Contact:
Technews Publishing (Pty) Ltd
1st Floor, Stabilitas House
265 Kent Ave, Randburg, 2194
South Africa
Publications by Technews
Dataweek Electronics & Communications Technology
Electronic Buyers Guide (EBG)

Hi-Tech Security Solutions
Hi-Tech Security Business Directory

Motion Control in Southern Africa
Motion Control Buyers’ Guide (MCBG)

South African Instrumentation & Control
South African Instrumentation & Control Buyers’ Guide (IBG)
Other
Terms & conditions of use, including privacy policy
PAIA Manual





 

         
    Classic | Mobile

Copyright © Technews Publishing (Pty) Ltd. All rights reserved.