OBJECTIVES

This course aims to provide a good understanding of the common industrial sensor as well as method to integrate the sensor into DAQ system. This course will specify the competency required to design and develop the critical elements supporting an industrial automation system, namely sensors, output devices and data acquisition system. The course aims to:

• Demonstrate the major types and operation modes of electrical sensors available in Industrial automation design
• Demonstrate the major types of output devices/actuators available in industrial automation design
• Apply the sensor selection skill to address the needs of application in the industrial automation design
• Construct a simple data acquisition application using signal conditioning circuit, USB data acquisition board with input/output devices and sensors given by instructor.

TARGET GROUP

The course is intended for Junior and senior Technician, Junior Engineer or Diploma holders.  

TRAINING METHODOLOGY

For each of the topic covered, the students are first taught the basic concepts. The principle of operation and its practical implementation are then covered. A developed software tools will be used to facilitate the lab practical.  Measurement of Op-Amp module using Oscilloscope, Digital Multimeter and Function Generator will be carried out to illustrate the principles and techniques taught.  Few application system integration lab exercises will be provided as well in order to prove the concept of integration between sensor and DAQ to develop a useful control application 

TRAINING PROGRAM OUTLINE

Day 1: 

Module 1: Sensors Technology and Applications

Objective:

• To familiar the concept of transducer and electrical sensor types in industrial automation
• To demonstrate the skill on selecting the appropriate sensors for industrial automation applications; understanding the factors, criteria’s and considerations needed.
• To review the various sensor performance characteristic and determine how they impact the applications design
• To understand the operation concept & sensor properties
• To discuss the general issues on measurement and source of errors

1.1. Introduction to Sensors

1.2. What is Transducers?

1.3. Physical Principles of Sensing

1.3.1. Proximity Sensor

1.3.2. Temperature Sensor

1.3.3. Magnetic Sensor

1.3.4. Photo-electric Sensor

1.3.5. Ultrasonic Sensor

1.3.6. Strain Gauges

1.3.7. Displacement Sensor

1.4. Sensors Selection

Module 2: Signal Conditioning and Communication Interface)

2.1 Why Signal Conditioning

2.2 Sources of Errors

2.2.1 Span or Dynamic Range

2.2.2 Accuracy

2.2.3 Repeatability

2.2.4 Stability

2.2.5 Time lag error

2.2.6 Reliability

2.2.7 Drift

2.2.8 Bandwidth

2.2.9 Sensitivity

2.2.10 Resolution

2.2.11 Calibration Errors

2.2.12 Hysteresis and Non-linear errors

2.2.13 Capacitive Coupling

2.2.14 Magnetic Coupling

2.2.15 Ground Loops

2.2.16 Over Voltage and Transients

2.2.17 EMI and RFI

2.2.18 Aliasing 

2.2.19 Crosstalk

2.3 Ways to preserve signal integrity

2.3.1 Shielding

2.3.2 Twisted Pairs

2.3.3 Cable Spacing

2.3.4 Anti-Aliasing Filters

2.4 Types of Signal Conditioning

2.4.1 Amplification

2.4.2 Attenuation

2.4.3 Filtering

2.4.4 Impedance Matching

2.4.5 Isolation

2.4.6 Multiplexing

2.4.7 Linearization

2.5 The Basics of Operational Amplifier (Op-Amp)

2.5.1 Inverting Amplifier

2.5.2 Non-Inverting Amplifier Stages

2.5.3 Op-Amp Voltage Follower (unity gain buffer)

2.5.4 Differential Amplifiers

2.5.5 Summing Amplifier

2.5.6 Instrumentation Amplifier (IA)

2.5.7 Zero and Span Circuits

2.5.8 Current to Voltage Conversion

2.5.9 Voltage to Current Conversion

2.5.10 Isolation Circuits

2.5.11 Filtering

Day 2: 

Module 3 : Data Acquisition System

Objective:

• To apply the data acquisition software and interface to read the sensor input and deliver output signal to control output devices.
• To control the input and output flow through the USB data acquisition system
• To differentiate the difference data acquisition methods, modify and apply them in the lab exercises.  

3.1 Communication Standard

3.1.1 A Guide to Signal Input Configuration

3.1.2 Single-Ended Inputs

3.1.3 Differential Inputs

3.1.4 Isolation

3.2 Introduction and Overview of Data Acquisition System (DAQ)

3.2.1 Sensors and Transducers

3.2.2 Field wiring and communications settings

3.2.3 Signal Conditioning

3.2.4 Data Acquisition Hardware

3.2.5 Data Acquisition Software

Day 3: 

Module 4: Applications Design

Objective:

• To build and develop a complete data acquisition system. 
• To identify type of sensor and output device driver to achieve the specific purpose requires in the application

4.1 Safety Interlock

4.2 Temperature Control

4.3 Event De-energizing

4.4 Light Seeking

4.5 Water Level or Fuel Level Measurement

4.5.1 Compliance