Sensor Manufacturing and Process Control

Go to Course: https://www.coursera.org/learn/sensor-manufacturing-process-control

Introduction

### Course Review: Sensor Manufacturing and Process Control **Course Overview:** The "Sensor Manufacturing and Process Control" course, offered by CU Boulder on Coursera, is a vital part of the Master of Science in Electrical Engineering program. As the fourth course in the specialization on Embedding Sensor and Motors, it continues the journey begun in prior courses—"Sensors and Sensor Circuits," "Motor and Motor Control Circuits," and "Pressure, Force, Motion, and Humidity Sensors." This course is designed for individuals who seek to deepen their understanding of sensor technology, process control mechanisms, and the intricacies of sensor manufacturing. **Course Syllabus Breakdown:** 1. **Process Control:** The course begins with an in-depth look at process control in industrial settings. Participants will engage with the theoretical underpinnings of second-order transfer functions and witness how these concepts streamline factory operations. A hands-on lab session with PID control using the PSoC system offers valuable experiential learning, crucial for grasping control systems applied in real-world manufacturing. 2. **Sensor Characterization:** This module shifts focus to optimizing sensor software for field performance. Students will learn to linearize non-linear sensor response curves, adjust outputs for temperature fluctuations, and calibrate sensors. By conducting labs on closed loop motor control, learners gain practical skills in ensuring sensor accuracy, which is integral to efficient sensor deployment in various applications. 3. **Advanced Sensors:** Transitioning into advanced technologies, the course covers radar level transmitters and their applications in process environments. Participants will also explore LIDAR system design for autonomous vehicles and customize sensors for medical applications, like pressure and flow sensors used in surgical and patient care settings. This blend of cutting-edge sensor technology ensures that learners are well-versed in contemporary advancements. 4. **Sensor Manufacturing:** The manufacturing process is unveiled in this comprehensive module, where MEMS technology is discussed. Topics include the micro-electronic connections that integrate MEMS with plastic molded chips and different sensor housings tailored for specific market demands. The course ensures that participants understand the rigorous testing required to guarantee sensor reliability in challenging environments. 5. **Course Projects:** Learners will apply their theoretical knowledge through hands-on assignments in PID control and closed loop DC motor control. These projects are pivotal for solidifying understanding and showcasing practical skills acquired throughout the course. **Overall Recommendation:** "Sensor Manufacturing and Process Control" is an essential course for electrical engineering students and professionals aiming to specialize in sensor technology and process control systems. It beautifully integrates theoretical knowledge with practical applications, facilitated by a strong framework of lab-based projects. Whether you are seeking academic credit or expanding your expertise, I highly recommend this course. The structure is well-thought-out, building progressively upon previous courses to ensure that learners have a firm grasp of essential concepts. The inclusion of real-world applications, particularly in advanced sensors and manufacturing processes, prepares students to enter various industries, from manufacturing to automotive and medical sectors. Moreover, CU Boulder’s commitment to quality education combined with the flexibility of Coursera's online platform makes this course a particularly appealing option for both full-time students and working professionals seeking to enhance their skills in the rapidly evolving field of sensor technology. If you’re looking to expand your competency in the domain of sensor manufacturing and process control, enrolling in this course is a compelling choice.

Syllabus

Process Control

In module 1 you will learn how companies perform process control in their factories. First, you will review how 2nd order transfer functions work, which is the theoretical basis for much of process control. Then you will learn how plant-wide control systems are implemented and details about the software protocols used to communicate between plant controllers and sensors. Then you will perform a lab for PID control with your PSoC system, which will get you some hands-on experience with this type of control system.

In module 2 you will learn how sensor software is adjusted for optimal performance in the field. First, you will review how non-linear sensor response curves are linearized for more predictable performance. Then you will learn how sensor output is automatically adjusted to account for wide ranges of ambient temperature. Next, you will review how sensors are calibrated, and the certification procedures that companies follow to demonstrate calibration capability. Afterwards, you will study how linearization, compensation, and calibration play into sensor accuracy specs. Finally, you will perform a lab for closed loop motor control with your PSoC system, which will get you some hands-on experience with closed loop systems.

In module 3 you will first learn how radar level transmitters work, and how they are used to provide accurate readings in all types of process tank conditions. Then you will learn about components and design issues for LIDAR systems used in self driving vehicles. Afterwards, we will teach you about how sensors are customized for medical applications. This includes pressure and temperature sensors that are implanted during surgical procedures, as well as pressure and flow sensors used in patient care equipment.

In module 4 you will learn how sensors are manufactured. First you will learn how MEMS construction is used to make miniature flow, pressure, and temperature sensors. Afterwards, we will teach you how micro-electronic connections attach the MEMS sensors to connections within plastic encapsulated chips. Then we will discuss how sensor chips are enclosed within sensor housings, and how different designs of housings are used for different applications. Then you will learn how sensors are tested for high reliability in the field.

This module contains the materials you need to complete the PID Control and Closed Loop DC Motor control lab assignments.