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Developing a sensor systemIntroductionDevelopment of a sensor system may range from installing an off-the-shelf sensor to developing a custom, turn-key sensor system. The success of such development depends on technical, management, and financial factors. If you are considering developing a sensor for your application, this note will help you to understand the development process. It details steps that MJC Optical Technology (MJC) may take in close cooperation with you to complete such development. A sensor development project typically consists of three phases: preparation, implementation, and support. The preparation phase includes mainly conceptual activities such as quantitative understanding of the object to be sensed (a product, defect, or process), identification of sensing technology, and developing sensor specification. The implementation phase includes sensor design and development activities. Finally, the support phase makes sure that you do not feel left alone with the newly acquired instrumentation and there is someone who will help you to smoothly introduce that instrumentation into the operation of your facility. This note is necessarily general. Depending on
the complexity of your application some topics may not apply or may apply to an
extent different than that discussed. Effective communicationThe success of a sensor development project
depends strongly on effective communication and cooperation between you, the
client, and us, the developer. Such a project is an iterative process and
typically involves tradeoffs dictated by technical and financial constraints
among others. Settling for a mutually acceptable solution in a reasonable
number of iterations requires effective and efficient communication pathways.
Preparation phaseIdentification of sensing technologyThe development of a sensor system begins with identification of applicable sensing technologies. This requires that we at MJC develop a thorough quantitative understanding of your product, production process, or research samples. In some cases, typically in industrial applications, it may be necessary for us to visit your facility and see what constraints it places on the sensing technology and sensor design. This information permits us to develop a conceptual model of relevant characteristic(s) of your product, sample, defect, and/or process which is crucial in selecting a sensing technology. With this model we can set out to identify sensing technologies which are most likely to succeed. We will also advise you on
This should enable you to identify constraints
which may be placed on your product / sample handling, or on the production
process. Our role at this stage is to select potential technologies and make
sure that you understand what each technology can do and what are its
requirements. Your role, as an expert in your product, sample, or production
process, is to evaluate implications of these requirements for your
application. At this time, we may also formulate preliminary ideas about the
sensor system and discuss these ideas with you so that you can evaluate their
implications. Development of the sensor specificationHaving settled for a candidate sensing technology, we can now adapt or create its mathematical model. This model permits us to develop a concept design of the sensor and establish or validate the sensor specification. Values and ranges of some parameters of the model may be unknown at this stage. For example, assume that your present defect detection technique is based on visual inspection. A skilled operator may spot the defect but he/she would not know the numerical difference between a "signal" from the defect and from a non-defective area of the product. If such is the case, we may need to develop a test fixture and use it to measure relevant parameters in a representative set of samples (with and without defects) provided by you. Concept design of the sensor relies on your
feedback as the prospective user of the sensor as some tradeoffs usually have
to be made. These tradeoffs are based on considerations of the performance,
reliability, ease of use, time planned for the development of the system, and
on the financial investment which you consider justifiable. EstimationMJC can now prepare an estimate which includes the project time-table as well as a time-table and magnitude of funds which you will need to invest in the project. We also examine potential technical and procurement challenges and outline specific contingency procedures to address these challenges. An estimate is by definition approximate. Its
accuracy and precision depend on the project stage. As a project evolves,
accuracy and precision of the estimate increase. In a "cutting edge"
project, it may be inpossible to give the total project estimate before a
critical part of the project is researched as a mini-project. Implementation phaseDesign and constructionWith the concept design and estimate approved by you, MJC can begin design and construction of the sensor system. In a complex application, one or more generations of sensor prototypes may need to be built before the final sensor is constructed. Development of a generation draws on experience obtained while developing the previous generation. Project reviews are instituted at key milestones during the sensor development cycle to ensure that
Installation/testing of the sensorAfter the sensor or its prototype has been
developed, it is installed by MJC at your plant / facility and your personnel
are trained in the sensor operation. If evaluation is required, a test period
is established which is expected to generate a sufficient evaluation data set.
During the test period, both the new sensor and your current sensing procedure
(if it exists) are both used to examine the same set of samples. The data
gathered are used to determine whether the projected system performance has
been achieved and what modifications, if any, need to be made to the sensor
system or to the way it is used. In a complex application, this step may be
followed by the development of the next-generation sensor prototype. Development of additional sensorsIf a quantity of sensors required to fit your
production / research volume will exceed our prototype development capacity we
may choose to propose a high-volume manufacturer. If you desire, MJC may
supervise the manufacturing process, and train the installers of the sensor
systems. MJC may also implement a review program aimed at perfecting the sensor
as part of development of these additional sensors. Such a review program sets
in place field-test and user-feedback procedures and permits you to continue
improving the sensor to reflect your evolving production process and product
specifications. DocumentationIn a complex project, at the time a prototype sensor is installed at your facility we can provide you only with preliminary documentation. However, at or following the installation of the final sensor, MJC will provide complete technical documentation of the developed sensor system. Such documentation typically
[Menu] Support phaseMJC provide technical support regarding the
sensor operation and may, at your request, also assist you in the
interpretation of measurement results. Technical support is usually executed by
phone and other means of remote communication. |
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