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Ultrastable Eddy Current Displacement Sensor Working in Harsh Temperature Environments With Comprehensive Self-Temperature Compensation
Ultrastable Eddy Current Displacement Sensor Working in Harsh Temperature Environments With Comprehensive Self-Temperature Compensation
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Article history: This paper proposes a method of self-temperature compensation for eddy current sensors (ECSs) dur-
Received 2 January 2014 ing rapid temperature changes. The temperature drift of the sensor impedance caused by the probe coil
Received in revised form 4 March 2014 and target temperature variations was discussed and analyzed. The proposed impedance measurement
Accepted 9 March 2014
method can distinguish the temperature drift caused by the sensor coil and the eddy currents in the
Available online 15 March 2014
target, and eliminate both of them in real time. A prototype ECS was manufactured and tested. The tem-
perature coefficients of the probe’s inductance and resistance caused by the target and the coil were
Keywords:
measured by a designed setup. The results show that the temperature drift of the inductance is mainly
Displacement measurement
Eddy current sensor (ECS)
caused by the target, and that of the resistance is mainly from the coil itself which is much larger than
Temperature coefficient (TC) the inductance’s drift. The prototype ECS that uses this new comprehensive self-temperature compen-
Coil impedance sation method achieved an ultra-low temperature drift of 4 nm/◦ C without any additional hardware or
Temperature compensation temperature sensor. It can work effectively even the environment temperature changes as fast as 10 ◦ C/h.
AC bridge
© 2014 Elsevier B.V. All rights reserved.
http://dx.doi.org/10.1016/j.sna.2014.03.008
0924-4247/© 2014 Elsevier B.V. All rights reserved.
H. Wang et al. / Sensors and Actuators A 211 (2014) 98–104 99
where Tc and Tt are the temperature of the coil and the target,
respectively. For most high-precision applications, the temperature
of the coil and the target may be the same. The temperature drift
of an ECS can be completely eliminated by using the method pro-
posed in Ref. [9]. However, this method hardly achieves effective
results if the coil and the target have different temperatures when
the temperature changes rapidly. For this situation, the tempera-
ture drift caused by the temperature variations of the coil and the
target must be separated to achieve comprehensive and effective
compensation.
As the ECS signal processing circuit directly detects the total
part of the effective impedance, without distinguishing the coil part
Fig. 1. Working principle and equivalent model of eddy current displacement sen- and the eddy current-caused part, the inductive part (L) and the
sor. resistive part (R) of the sensor coil [Eq. (2)] can be rewritten as
temperature variation can be eliminated in real time. The ECS L = f (x, Tc , Tt )
(3)
prototype that uses this comprehensive self-temperature com- R = g(x, Tc , Tt )
pensation method achieved a TC as low as 4 nm/◦ C even the
environment temperature changes as fast as 10 ◦ C/h (close to According to Eq. (1), TC of the eddy current-caused part
the performance 2.6 nm/◦ C when the temperature changes slowly impedance (Le and Re ) depends on the measurement distance x,
about 1 ◦ C/h [9]). The new method is solely based on signal which means that the TC of the ECS is not constant. Since the
processing circuits and does not require any additional hardware measurement range is usually only tens of microns and the temper-
of the sensor coil or temperature sensor. ature fluctuation is a few degrees for a high-resolution ECS system,
the inductive part (L) and the resistive part (R) of the effective
2. Working principle impedance [Eq. (2)] can be simply expressed as the linear com-
bination of x, Tc and Tt
Generally, an ECS system consists of a sensing coil and a con-
L = K11 x + K12 Tc + K13 Tt + L0
ductive target [Fig. 1(a)]. For a non-ferromagnetic target, the basic (4)
interaction between the probe coil and the target metal can be R = K21 x + K22 Tc + K23 Tt + R0
described by the transformer model [Fig. 1(b)]. The primary of the
transformer represents the sensor coil, which has a serial resis- For a specific sensor coil and target material, Kij (i = 1, 2; j = 1, 2,
tor Rc and an inductor Lc , and the secondary of the transformer 3) are constants and can be measured previously and used as cor-
represents the target, with a serial resistor Rt and an inductor Lt . rection parameters. Except for measuring the inductance and the
According to Kirchhoff’s law, the effective impedance of the ECS resistance, one of the temperatures (Tc or Tt ) also needs to be mea-
(input impedance of the transformer) can be obtained [10] sured at the same time. Then, the true displacement information x
⎧ can be obtained by eliminating the drift caused by the target and
⎪ ω2 M 2
⎪
⎨ R = Rc + R2 + (ωL )2 Rt = Rc + Re
the coil temperature variations completely. Measuring the tem-
t t perature of the target requires an additional temperature sensor,
(1)
⎪
⎪ ω 2M2 which results in an electronic connection to the target, whereas
⎩ L = Lc − 2 L = Lc − Le
2 t the coil temperature can be obtained by measuring the coil resis-
Rt + (ωLt )
tance, which is a better choice. The relationship between the coil
where ω is the angular frequency of the coil’s excitation, and Re and resistance and its temperature can be written as
Le are the eddy current-caused resistance and inductance, respec-
Rc = Rc0 + Kc Tc (5)
tively. M is the mutual inductance between the coil and the target,
which depends on the distance
x between the coil and the target, Thus, the coil temperature can be obtained by
and can be written as M = k Lc Lt (0 < k < 1). k is the coupling factor
Tc = (Rc − Rc0 )/Kc (6)
between the primary and the secondary of the transformer, which
is a function of the distance x. The TCs of the inductance Lc and Lt Substituting Eqs. (6) into (4) and solving Eq. (4), the
mainly depend on the coefficient of thermal expansion of the coil temperature-independent information x can be calculated. With-
or the equivalent model of the target. For a specific ECS system with out any additional hardware, the position information x can be
constant geometric parameters, the inductance of the coil and the simply extracted by adding the R, L, and Tc signals with different
100 H. Wang et al. / Sensors and Actuators A 211 (2014) 98–104
ec Rs (Rc − R) ec Rs
Uc = + · Rc (8)
(R + Rc )(Rs + Rc ) (R + Rc )(Rs + Rc )
3. Device description
Based on Eqs. (7) and (8) and the signal processing circuit (shown expansion. The displacement drift from the frame’s thermal expan-
in Fig. 3), the three channel output voltage are sion may be even larger than the inherent temperature drift of the
⎧ ec Rs
sensor itself. Furthermore, heating the target (aluminum plate) or
⎪
⎪ UC = · Rc · K0 · K1 the copper coil alone and keeping the temperature of the other parts
⎪
⎪ (Rs + Rc )(R + Rc )
⎪
⎨ constant is nearly impossible, which prevents the measurement of
eRs L the coefficients of the impedance to the target temperature and the
UL = · · K0 · K2 (9)
⎪
⎪ 2ωL L coil temperature.
⎪
⎪
⎪
⎩ eRs R To solve the first problem, a setup [9] with very low tem-
UR = · · K0 · K3 perature drift was specially designed [Fig. 4(a)]. A micrometer
2ωL Rs + R
head was assembled on an aluminum frame, and the ECS probe
where e and ec are the amplitudes of the excitation voltage, K0
is the gain of the differential preamplifier, and K1 , K2 , and K3 are
the gain of the three output amplifiers, respectively. Rc is the
variation of the DC resistance of the coil, which is caused by the
coil temperature variation. In our experiments, e = 1.0 V, ec = 1.0 V,
L = 2.07 H, Rs = 7.2 , Rc = 4.6 , R = 5.8 , f = 1 MHz, ωL= 13.0 ,
K0 = 61, K1 = 30.09, K2 = K3 = 29.29. Thus, the variation of inductance
and resistance of the coil can be obtained by measuring the value
of UL and UR , and calculated by using
⎧
⎪
⎨ L =
L
=
UL
L 494.5
(10)
⎪
⎩ R = R = UR
R 220.6
where L and R are the normalized variation of the coil’s
inductance and resistance, respectively, and are dimensionless
quantities.
Fig. 5. ECS probe’s temperature drift and compensation results during heating and cooling (a) the change of the three output channel and the temperature within the process.
(b) The target temperature and the coil temperature with time. (c) The displacement output of the ECS that uses the old self-correction method within the process. (d) The
displacement output of the ECS that uses the comprehensive compensation within the process.
was assembled coaxially with the spindle of the micrometer. A temperature increase of the surrounding environment. A Pt100
0.2 mm thick aluminum plate was selected as the target plate. A was placed near the sensing coil to measure the temperature
180 m thick muscovite plate was used to determine the distance inside the aluminum tube. This temperature was used to calculate
between the coil and the target surface. When the micrometer the thermal sensitivity of the coil impedance. The test setup was
screw spindle moved to the left to compress the elastomer at a heated and cooled slowly to ensure constant temperature through-
suitable force, the distance between the coil on the probe and out the inner space of the aluminum tube. The well designed
the target surface was fixed to the thickness of the muscovite circuit was placed in an air conditioned room and regarded as
plate. The muscovite plate and the probe maintained contact, stable.
and the thermal expansion of the muscovite plate’s thickness is For the second problem, the TC of the coil impedance was mea-
only 1.6 nm/◦ C (with a general thermal expansion coefficient of sured first. The probe coil without a target was placed in the thermal
9 ppm/◦ C for muscovite). The thickness variation caused by ther- isolation box and heated. A new well matched bridge [similar to
mal stress is also negligible as the stiffness of the muscovite plate the one shown in Fig. 2(a)] was used to measure the TC of the coil’s
is much greater than that of the elastomer. Therefore, the dis- inductance (mL ) and resistance (mR ); the obtained TCs are 12.3 and
tance between the target surface and the coil on the probe can 3133 ppm/◦ C, respectively. Then, the total (effective) impedance’s
be regarded as constant during the entire measuring process. The TC was measured by heating the whole coil-target unit with a
setup was placed in an aluminum tube surrounded by a thermal fixed distance simultaneously and slowly. The TC of the resistive
isolation box [Fig. 4(b)]. A heating wire wound on the aluminum part (q) is 2292 ppm/◦ C, and the TC of the inductive part (p) is
tube was used to generate thermal energy and induce a uniform 255.6 ppm/◦ C.
Table 1
Parameters of impedance and temperature coefficients.
Parameters L R Lc Rc Le Re
Thus, the TC of the effective impedance caused by the temper- about 150 nm, which appears at the point where the coil and the
ature drift of the coil part and that of the eddy current part can be target have the maximum temperature difference. Furthermore,
written as the curve trend of UL [Fig. 5(a)] is similar to the temperature curve
of the target, while the curve trend of UR is similar to the temper-
L = pL · T = p(Lc − Le ) · T = (mL Lc + nL Le ) · T
(11) ature curve of the coil, which is consistent with the temperature
R = qR · T = q(Rc + Re ) · T = (mR Rc + nR Re ) · T coefficients in Eq. (16). The displacement output of the ECS obtained
by using the new self-correction method is shown in Fig. 5(d),
where p, q, mL , mR are known, nL and nR are the TC of the eddy which shows that the total drift during the process is lower than
current caused inductance and resistance, which can be calculated. 30 nm. Hence, the temperature drift of an ECS that uses the pro-
The parameters and the TC of the resistance and inductance of the posed temperature compensation method is below 4 nm/◦ C in an
coil are listed in Table 1. environment where the temperature changes at a speed of about
The ECS signal processing circuit directly detects the total part of 10 ◦ C/h.
the effective impedance without distinguishing the coil part and the
eddy current caused part. When the temperatures of the target and
the coil change differently, the temperature drift of the impedance 5. Conclusion
can be written as
L = pc L · Tc + pe L · Tt = mL Lc · Tc − nL Le · Tt The results prove the validity of the method presented in the
(12) second section. Separating the temperature drift caused by the
R = qc R · Tc + qe R · Tt = mR Rc · Tc + nR Re · Tt target temperature variation and the coil temperature variation,
and measuring the coil temperature in real time can eliminate the
where pc and pe are the TC to the total inductance caused by the
temperature drift of an ECS nearly completely. The results indi-
coil and the target temperature variations, respectively, and qc and
cate that an ECS with this proposed self-correction method can
qe are the coefficients to total resistance. According to Table 1, pc ,
achieve an ultra-low temperature drift of 4 nm/◦ C even in an envi-
qc , pe , and qe can be easily calculated. In summary, the coefficients
ronment where the temperature changes rapidly; this temperature
in Eq. (4) are all known, and Eq. (4) can be rewritten as
drift is only one-fifth of the TC obtained by using the old self-
L = dL x + pc Tc + pe Tt + L0 = 1681x + 28.22Tc + 225.0Tt + L0 correction method under the same conditions. This method ensures
that a high-resolution ECS remains very stable even in a harsh
R = dR x + qc Tc + qe Tt + R0 = −1007x + 2485Tc −192.8Tt + R0
temperature environment. As an additional result, the measured
(13) coefficients show that the temperature drift of the inductance part
where the unit of L , R , L0 and R0 are ppm, m for x, and ◦ C for is mainly from the target, while that of the resistance part is much
Tc and Tt . L0 and R0 are constant. larger and mainly from the coil itself. These findings provide some
For simplifying the correction, substituting Eqs. (10) into (13) guidance for designing a high-performance ECS, especially high-
yields resolution and low-temperature drift ECS. The residual drift after
the correction may come from several aspects, such as the temper-
UL = 0.8313x + 0.0139Tc + 0.1113Tt + UL0 ature drift of the probe cable’s resistance, the error of the correction
(14) coefficient, the variation of the TC of the ECS at different temper-
UR = −0.2222x + 0.5482Tc − 0.0425Tt + UR0
atures, and the temperature drift of the signal processing circuit.
As an additional result of the experiment above, the relationship A relative long probe cable is needed for universal displacement
between the coil temperature Tc and the output voltage UC is sensor to adopt different kinds of applications, but long cable will
reduce the temperature stability and performance of an ECS. Using
Tc = 27.6 − 7.6 × UC (15) this method, the cable resistance variation has no influence to the
Substituting Eqs. (15) into (14) and solving the equation yields thermal stability, since the cable resistance can be regarded as
part of the coil resistance. Generally, the cable and coil resistance
x = 0.7069UL − 1.856UR − 7.659UC + x0 have similar temperature variations, which is a common situation
(16)
Tt = 13.73UL + 3.670UR + 57.57UC + Tt0 according to the coil packaging. When the temperatures of the coil
and the cable change differently, the 4-wire measurement method
where the unit of the three voltages is Volt(V), m for x, and ◦ C for could be adopted.
Tt . x0 and Tt0 are constants that can be adjusted by the offset nulling This paper presents a method that can remarkably improve
of the three output amplifiers according to the target position and the stability of an ECS by using self-temperature compensation
temperature point of the ECS probe. when the environment temperature changes rapidly. The impact
To verify the effect of this temperature compensation method, factor of the temperature drift of the ECS was discussed and ana-
the ECS with a fixed distance between the target and the coil lyzed, and the temperature coefficients caused by the coil and
was placed in the thermal isolation box, which was then heated the target were measured. The ECS that uses this comprehensive
rapidly and cooled naturally. The voltage changes of the three compensation method is mainly based on the signal processing
output channel and the temperature variation during the heat- of the sensing coil. Thus, the ECS is low cost and has a sim-
ing and cooling process were shown in Fig. 5(a). The temperature ple structure. The high-resolution ECS that uses the proposed
curve shows that the temperature rose rapidly by 8.5 ◦ C within compensation method will have competitive advantages in most
about 50 min and then came down slowly in the next 4.5 h. The industrial applications, especially when the environment temper-
coil temperature is calculated from the voltage UC and shown in ature is not well controlled, such as the hot metal production
Fig. 5(b) with the temperature of the target (measured by Pt100) line in the factory, or the precision equipment in the wild. This
during the process. The curves show that the temperature of the method can be directly used to non-contact metal temperature
probe coil changes more slowly than that of the target, and the measurement, since it can measure the displacement, the coil tem-
coil temperature does not remain the same as the target tempera- perature and the target temperature at the same time with only
ture when the environment temperature changes too fast. Fig. 5(c) one detection coil. In addition, this techniques could be used for
shows the displacement output of the ECS that uses the old self- any impedance measurement based eddy current testing applica-
correction method proposed in Ref. [9]. The maximum error is tions.
104 H. Wang et al. / Sensors and Actuators A 211 (2014) 98–104
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