KJS 2343/KJS 3113

Industrial Measurement and

Instrumentation

Lecture 1
Introduction to Instrumentation and Measurement
System

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CLO 1: Describe the basic elements in

measurement and instrumentation system
Measurement systems
Application in measurement
Functional elements
Standard and Calibration.

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Measurement System
Measurement is the act of assigningaspecicvalue to a measurand

(physical value).
Mass, distance,time, temperature, force, and other physical quantities, as well as t
he properties of matters,materials, and devices, must be measured and describe in
common terminology.
Performance of a measuring instrument is to be specified in terms of static and
dynamics performance parameters
Measuring instruments are designed to generate a fixed and reproducible
magnitude of the measurand which is expressed by a number(magnitude ratio)
followed by the matching unit,e.g length of 2.5m
Measurement provides quantitativeinformation on the actualstate of
the measurand that otherwise could only be estimated.

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Measurement System
Scope application of measurement {reported from ISO/IECGuide98:2008Uncertaintyof
MeasurementGuidetotheExpressionofUncertaintyinMeasurement(GUM) (ISO,2008

)}

To maintain quality control and quality assurance in production;

To comply with and enforcing laws and regulations;
To conduct basic/applied research and development, in science a

nd engineering;
To develop, maintain and compare international and national ph
ysical reference standards,
Reference materials, and also to achieve traceability to national s
tandards.

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According toISO/IECGuide99:2007InternationalVocabularyofMetrologyBasicandGeneral

measurement is dened as

ConceptsandAssociatedTerms(VIM) (ISO, 2007),

processofexperimentallyobtainingoneormorequantit

yvaluesthatcanreasonablybeattributedtoaquantity

Measurement is the process of determining the

amount, degree or capacity by comparison with the
accepted standards of the system units being used.
Instrumentation is a technology of measurement
which serves sciences, engineering, medicine and
etc.
Instrument is a device for determining the value or
magnitude of a quantity or variable

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Thus measurement is an experimental science and most experiments are classied

into following four categories (Dunn, 2010):
1.Variationalexperiments.
These are carried out with an objective to establish the
mathematical relations between the experiments variables.
2.Validationexperiments.
These are carried out to validate a specic hypothesis.
3.Pedagogicalexperiments.
These are aimed to demonstrate something that is already known.
4.Explorationexperiments.
These are conducted to explore an idea or possible theory.

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Measurement Process
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Measurement Process

A process to present an observer with a numerical value

corresponding to the variable being measured by using
appropriate instrument
Input
True value
of variable

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Measurement
system

Output
Measured value
of variable

Before measurement process we have to ensure:

1. Methods/procedures of measurement
2. Characteristics of the parameter
3. Quality: time and cost, instrument capabilities
knowledge of measurement, acceptable result
4. What instrument to use
During the measurements we have to ensure:
1. Quality : best instrument chosen, suitable position when taking the data, etc..
2. Safety : electric shock, overloaded, instrument limits, read instrument manual
3. Sampling : obverse parameter changing, taking enough sample
After measurement
1. Analyse the data mathematically/statistically
2. Full result must be reported completely and accurately

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Experimental Test Plan

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A well thought-out experimental test plan includes

(1) An identification of pertinent process variables and parameters.
(2) A measurement pattern.
(3) A selection of a measurement technique and required equipment.
(4) A data analysis plan.
Random tests-- a random order set to the applied independent
variables.
Replication-- an independent duplication of a set of
measurements under similar
controlled conditions.
Concomitant Methods-- two or more estimates for the result,
each based on a different method
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Why Need Instrumentation and Product Testing in Manufacturing?

The goal of Manufacturing or Production of parts/products is to
produce them economically, in compliance with design
specifications, which assure the proper function and service of the
manufactured product in its expected life. The roles of
Instrumentation and Product Testing are:

Quality, Safety and Reliability Control

Process Control and Automation
Design and Production of Intelligent Products

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Some application examples:

(a) Manual Process Control

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(b) Automatic Inspection for Process Control

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(c) Quality Inspection

(d) Indexing for Process Control

Therefore, the basic purpose of

Instrumentation (or Engineering
Measurement) in Manufacturing(mechnaical)
is to ensure and verify the agreement of
the product, in various stage of
manufacturing, with compliance to the
specifications of the design, aiming to
achieve and Economical and Efficient
production of High Quality and Reliable
products.

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General Measurement System

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A measuring instrument can be described in terms of its functions

elements, and these elements form the bridge between input

measurement system and the system output, a
quantity that is used to infer the value of the measurand.

The measurand is the physical quantity to be measured, i.e. temperature,

pressure, flow rate, strain, displacement, etc.

Most measurement systems fallwithin the general framework consisti

ng of three functional stages (Holman, 2001):

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Measurement system consist of

1. Basic Functional Elements

2. Auxiliary Functional elements

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A complete measurement system

All measuring systems include three basic elements:

Transducer

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Signal
conditioner

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Recorder or
Display

A complete measurement system

All measuring systems include three basic elements:

Transducer

Signal
conditioner

Recorder or
Display

detect and convert the physical quantity into a more

usable form: a mechanical, pneumatic, hydraulic or
electrical signal.
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A complete measurement system

All measuring systems include three basic elements:

Transducer

Signal
conditioner

Recorder or
Display

modify the signal to a desirable output:

amplifier, filter, A/D converter, etc.
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Signal Conditioning

1.Takes output of the sensing element coz too small to operate

2. Convert the output into a form more suitable for further processing.
e,g mechanical linkage, electrical cable, pnuematic transmission
3.Example:
Deflection bridge converts an impedance change into a voltage change
Amplifier amplifies milivolts to volt.
Oscillator converts an impedance into a variable frequency volatge

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A complete measurement system

All measuring systems include three basic elements:

Transducer

Signal
conditioner

Recorder or
Display

Transmission Path: noise and attenuation

show and record the measurand:
analog or digital
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Data Presentation

* Presents the measured value in a form which

can be easily recognised by the observer.
* Examples:
1.
A simple pointer scale indicator
2.
Oscilloscope
3.
Chart recorder
4.
Alphanumeric display
5.
Visual display unit

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Example of identification of Functional Elements

25

glassbulb mercury thermometer

Mercury acts as the sensor whose volume changes with change in its temperature. The
transducer is the thermometer-bulb where the change in mercury volume leads to mercury
displacement because of the bulbs xed volume. The stem of the thermometer is the
signal-conditioner which physically amplies the mercury displacement and the graduated
scale on the stem offers the required temperature indication.

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Example: A Pressure gauge

40

50

60

70
80

30

90

20

100

10
0

kPa

110

Pressurized Gas Pipe

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Bourdon-tube (oval cross-section)

detector transducer stage
Increased pressure
causes movement of
tube in this direction

Sector
Pointer and dial
are indicator stage
Pressure
source
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Sector and pinion

are modifying stage

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Pedometer
Transducer?
Mass
Signal Conditioner?
Counter
Display?
LCD
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Unit of Measurement
It is a well-known saying that the knowledge about
anything is complete only when if it can be
quantified (expressed in numbers) correctly.
Therefore, in conjunction with the above need, for
every kind of quantity measured, there must be a
unit to measure it and express it in numbers of that
unit.
Furthermore, in order that this unit is followed by all
and not one who is taking the measurements, there
must be a universal standard and the various
units for various parameters of importance must be
standardised.
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The National Institute of Standards and Technology (NIST) has the primary responsibility
to maintain standards for such quantities as length, time, temperature, and electrical quantities for
the US

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What does a Standard mean?

Two meanings:
(1) Documents of regulations or
guidelines for standardization, and
(2) Physical representation of the unit
of measurement

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Measurement Standards and Calibration

Measurement Standard

Standard is an instrument or device having a recognised stable

value that is used as a reference.

Measurement standard can be categorised into:

InternationalStandard

Example:BSI(BritishStandardInstitution),IEC(International
ElectrotechnicalCommission),ISO(International
OrganisationforStandardisation)

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Primary Standards

A primary standard is used as a fundamental definition of the size of a

physical unit. Primary standards are specified by the provisions of an
international treaty

- Example: Malaysia SIRIM National Metrology Lab

North America National Bureau of Standards (NBS)
in Washington D.C
Secondary Standards

A secondary standard is a copy of a primary standard that can be

used routinely for making measurements

- Example: SIRIM, Pusat Penyelidikan Pertahanan, Local

universities, industries.
Working Standards
-Example: SIRIM, local universities, industries.

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Measurement Standard
(International Standard)
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Are defined by international agreements. These

standards are maintained at the International

BureauofWeightandMeasuresinParis,
Frances.
They are periodically evaluated and checked by
absolute measurements in term of the
fundamental units of physics.
They
represent
certain
units
of
measurementto the closest possible accuracy
attained by the science and technology of
measurement and used for comparison with
primarystandards.
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Measurement Standard
(Primary Standard )
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Are maintained at institution in various countries

around the world, such as the National Bureau of

Standard on Washington D.C, SIRIM in Malaysia.
The primary standards are not available for use
outside the national laboratories.
Their principle function is to calibrateandverify
thesecondarystandards.
Also known as National Standard

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Measurement Standard
(secondary standard)
39

Used as the basic referencestandardsused by

measurement & calibration laboratories in the

industry.
Each
industrial laboratory is completely
responsible for its own secondary standards.
Each laboratory sends its secondary standards to
the national standards ( primary standards)
laboratory for calibration.
After calibration, the secondary standards are
returned to the industrial uses with the
certification and checked periodically.
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Measurement Standard
(working standard)
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Working

standard is the principle tools of a

measurement laboratory and the lowest level of
standards.
They are used to check and calibrate the
instruments used in the laboratory or to make
comparison measurement in industrial application.
As example, the standard resistor, capacitors,
inductor usually found in an electronics laboratory
are classified as working standards.

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subsequently to reduce errors in measurements. There is a hierarchy of standards

arranges themselves in order of decreasing accuracy with the primary standards being t
accurate (Doebelin, 2004). Tables 1 and 2, respectively, list hierarchy of standards and
associated with various levels of temperature standards.
Primary standard
Transfer standard
Local standard
Working standard

Maintained as absolute unit standard

Used to calibrate local standards
Used to calibrate working standards
Used to calibrate local instruments

Table 1. Hierarchy of Standards (Figliola & Beasley, 2011).

Level
Primary
Transfer
Working
Local

Method
Fixed thermodynamic points
Platinum RTD
Platinum RTD
Thermocouple

Uncertainty [C]
0
0.005
0.05
0.5

Table 2. Examples of Temperature Standards (Figliola & Beasley, 2011).

Calibration is the process of comparison of the output of a measuring system to the val
range of known inputs and the results may be expressed by a statement, calibration fu

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Calibration
A process of comparing and correcting the output

of an instrument with the standard value.

An instrument need to be calibrated once its output

is out of specification.

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Calibration
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Calibration Procedures can be classified as follows

Primary calibration

When device/system is calibrated against primary standard

Eg weight scale calibrated against SIRIM

Secondary Calibration

When a secondary calibration device is used for further calibrating

another device of lesser accuracy
Widely used in general laboratorary practice and industry because
they are practical sources

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Calibration
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Direct calibration with known input source

In general, same order of accuracy as primary calibration
Therefore device that are calibrated directly are also known as
secondary calibration device
Indirect calibration
Based on the equivalence of two different device that can be
employed for measuring a certain physical quantity

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Calibration
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Routine calibration

Procedure of periodically checking the accuracy and proper functioning of an

instrument with standards that are known to be accurately reproducible
Steps of calibration procedure
Visual inspection of the instrument for the obvious physical defects
Checking the instrument for proper installation in accordance with the
manufactures specification
Zero setting of all the indicators
Leveling the devices which require precaution
Recommended operational tests to detect major defects
Instrument should preferably be calibrated in ascending as well as
descending order of the inputs value to ensure that errors due to friction
are accounted for
The calibration device should have superior level of traceability of
standards as compared to calibrated device

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Thank you

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