One day workshop on Calibrations of Sensors

Date: August 8th 2015

Sensors and Actuators
Different types of sensors have been developed over a period of last 100 to 150 years. Sensor
made our life easy, fast and automatic. Sensors and actuators can be interfaced to make a
hands free intelligent systems.

Classification of Sensors

Mechanical sensors
Electro-mechanical sensors
Electronic (Analogue and Digital) sensors

Criteria to select sensor

There are certain features which have to be taken in account while selecting the sensor
Accuracy required
Speed/Swiftness of response required
Range of measurement involved
Current/Voltage output from sensor available
Reliability/Dependability of sensor
Size/Mass of the sensor
Environment like vibrations, heat, radiation, pressure, dampness, chemicals, etc.
Cost of the sensor as well as other protection circuits, components required
Need for Calibration
Calibration is simply the comparison of instrument performance to a standard of known
accuracy. It may simply involve determination of deviation ofinstrument reading to standard
reading to minimize the error. Properly calibrated equipments provide confidence that your
product/ services meet their specifications.

The accuracy of electronic components used in all instruments naturally drifts over time
Calibration quantifies and improves the measurement performance of an instrument
Reduced measurement errors
Consistency between measurements
Assurance of accurate measurements
Reduced rejection / rework

Accuracy and precision

Accuracy is closeness of a measured value to a standard or known value.
Precision is closeness of two or more measurements to each other.
Following picture simplifies the difference between accuracy and precision

Method for calibration of temperature sensors

1. Identify the type of Unit Under Calibration(UUC) and select the suitable master for
calibration.
2. Insert the UUC andmaster sensor into the temperature bath / furnace at equal position.
3. Make the proper connections of UUC and universal calibrator and switch on the
temperature furnace / oil bath.
4. Set first reading, as selected in calibration points and allow UUC andmaster to become
stable.
5. After reading reaches stable state, note down the observed reading on universal
calibrator in the Raw Data Sheet.
6. Repeat step 4, and take at least three readings covering the entire range of UUC.
7. Note down the readings observed in Step 5 in the respective Raw Data Sheet.
8. After completion of calibration, set the temperature bath / furnace to ambient temp.
9. Once the temperature of the furnace / oil bath reaches to ambient temperature remove
the UUC and master sensor.
10. Calculate the errors by using following formulas,
Error % FSD = {( UUC Reading Std Reading ) / Full Range of UUC} x 100
Error % rdg = {( UUC Reading Std Reading ) / UUC Reading} x 100.
Error = ( UUC Reading Std Reading )
Method for calibration of probe with DRO ( LVDT Sensor )
1. Mount the UUC firmly on the comparator stand. Ensure that it is not tilting to any side
and the movement of the plunger is free over the entire range.
2. Set the zero on UUC by taking 2mm (Minimum) size slip gauge as a base, which has to
beexcluded while recording the readings in the Raw Data Sheet.
3. Take the readings on the UUC by passing incremental size slip gauges as per the
following
table till the entire range of UUC is covered.UUC having least count
0.0001, 0.0005, 0.001 0.002 mm and having any range in between 0-50 mm. Following
table shows the incremental slip gauge sizes.
Revolution
1
2

Incremental Slip Gauge Size

2.01, 2.02, 2.03, 2.04, 2.05, 2.06, 2.07, 2.08, 2.09, 2.10
2.11, 2.12, 2.13, 2.14, 2.15, 2.16, 2.17, 2.18, 2.19, 2.20
2.21,2.22, 2.30

No. of Readings
20
06

3
4
5

2.31,2.32, 2.40
2.41,2.42, 2.50
2.51,2.52, 2.60
2.65, 2.70
2.75, 2.80
2.85, 2.90
2.95, 3.00

06
04
04

Above 1 mm range following guidelines should be used as a basis for taking the number
ofreadings.
Above 2 3 mm
: Take 10 Equivalent Readings per revolution.
Above 3 5 mm
: Take 5 Equivalent Readings per revolution.
Above 5 10 mm
: Take 2 Equivalent Readings per revolution.
Above 10 25 mm
: Take 1 Reading per revolution.
Above 25 50 mm
: Take 1 Readings per 2 revolutions.
4. Note down the respective readings observed in Step 3 in the respective Raw Data
Sheet.
Method for calibration of pressure gauge
1. Remove the air bubbles from the media used in the comparison test pump.
2. Select the master, suitable to range of UUC, and connect the master gauge and UUC to
comparison test pump.
3. Depending on the measurement uncertainty aimed at, one or several measurement series
are necessary. Refer following table for measurement series.
4. The comparison between the measurement values for calibration item and reference or
working standard performed by adjustment of the pressure according to the indication
of the UUC.
5. The time for preloading at the highest value and the time between two preloadings
should be at least 30 seconds which shall be ensured by digital stop watch. After
preloading and steady-state conditions have been reached and the calibration item
permission the indication of the calibration item is set to zero.
6. The calibration is to be carried out in measurement points uniformly distributed over the
calibration range.
7. Apply pressure uniformly in UP (Forward) direction and set the first reading on UUC
by applying the pressure, as per the selected calibration points and note down the
reading on master gauge and UUC in the Raw Data Sheet.
8. Repeat step 5, and take minimum five readings covering the entire range of UUC.
9. Release the pressure uniformly in Down (Reverse) direction and set the last reading
on UUC by applying the pressure, as per the selected calibration points and note down
the reading on master gauge and UUC in the Raw Data Sheet.
10. Repeat step 7, and take five readings equivalent as taken in step-6, covering the entire
range of UUC, in down (reverse) direction. Calculate the Error,
Error = Mean Value Test Point Reading
11. Note down the readings observed in Step 7 in the respective Raw Data Sheet.