FLEXIBLE LOW-COST HW/SW ARCHITECTURES FOR TEST, CALIBRATION AND CONDITIONING OF MEMS SENSOR SYSTEMS

During the last years smart sensors based on Micro-Electro-Mechanical systems (MEMS) are widely spreading over various fields as automotive, biomedical, optical and consumer, and nowadays they represent the outstanding state of the art. The reasons of their diffusion is related to the capability to measure physical and chemical information using miniaturized components. The developing of this kind of architectures, due to the heterogeneities of their components, requires a very complex design flow, due to the utilization of both mechanical parts typical of the MEMS sensor and electronic components for the interfacing and the conditioning. In these kind of systems testing activities gain a considerable importance, and they concern various phases of the life-cycle of a MEMS based system. Indeed, since the design phase of the sensor, the validation of the design by the extraction of characteristic parameters is important, because they are necessary to design the sensor interface circuit. Moreover, this kind of architecture requires techniques for the calibration and the evaluation of the whole system in addition to the traditional methods for the testing of the control circuitry. The first part of this research work addresses the testing optimization by the developing of different hardware/software architecture for the different testing stages of the developing flow of a MEMS based system. A flexible and low-cost platform for the characterization and the prototyping of MEMS sensors has been developed in order to provide an environment that allows also to support the design of the sensor interface. To reduce the reengineering time requested during the verification testing a universal client-server architecture has been designed to provide a unique framework to test different kind of devices, using different development environment and programming languages. Because the use of ATE during the engineering phase of the calibration algorithm is expensive in terms of ATE’s occupation time, since it requires the interruption of the production process, a flexible and easily adaptable low-cost hardware/software architecture for the calibration and the evaluation of the performance has been developed in order to allow the developing of the calibration algorithm in a user-friendly environment that permits also to realize a small and medium volume production. The second part of the research work deals with a topic that is becoming ever more important in the field of applications for MEMS sensors, and concerns the capability to combine information extracted from different typologies of sensors (typically accelerometers, gyroscopes and magnetometers) to obtain more complex information. In this context two different algorithm for the sensor fusion has been analyzed and developed: the first one is a fully software algorithm that has been used as a means to estimate how much the errors in MEMS sensor data affect the estimation of the parameter computed using a sensor fusion algorithm; the second one, instead, is a sensor fusion algorithm based on a simplified Kalman filter. Starting from this algorithm, a bit-true model in Mathworks Simulink(TM) has been created as a system study for the implementation of the algorithm on chip

Mixed signal approach for rapid prototyping of a compact smart pebble for sediment transport monitoring in river beds

Low-cost accelerometers and gyro ICs were used to develop a smart sediment particle to study the sediment transport in rivers. With strap-down MEMS, battery, a processing subsystem and memory, this self contained unit captures semiprocessed data for durations up to 15 minutes. In a mixed-mode design, analog multiplier ICs with limited digital circuits transform the body frame data to a reference frame using Euler angles, with adequate accuracy despite cumulative errors. For 3D motion, up to nine sensor inputs from three orthogonal modules are coupled to a multiplexed analog processing module, and processed by a digital module for data conversion and storage. Despite the simplified mathematics used, experimental data from the proof-of-concept system provided adequate accuracy. Subsequent processing of the raw sensor data using an external PC program with smart algorithms allowed the comparison of accuracy of the mixed mode approach. The adopted mixed signal design approach helps the packaging requirements due to the specific nature of the problem with short recording durations

Prototyping a new car semi-active suspension by variational feedback controller

New suspension systems electronically controlled are presented and mounted on board of a real car. The system consists of variable semi-active magneto-rheological dampers that are controlled through an electronic unit that is designed on the basis of a new optimal theoretical control, named VFC-Variational Feedback Controller. The system has been mounted on board of a BMW Series 1 car, and a set of experimental tests have been conducted in real driving conditions. The VFC reveals, because of its design strategy, to be able to enhance simultaneously both the comfort performance as well as the handling capability of the car. Preliminary comparisons with several industrially control methods adopted in the automotive field, among them skyhook and groundhook, show excellent results

Platform-based design, test and fast verification flow for mixed-signal systems on chip

This research is providing methodologies to enhance the design phase from architectural space exploration and system study to verification of the whole mixed-signal system. At the beginning of the work, some innovative digital IPs have been designed to develop efficient signal conditioning for sensor systems on-chip that has been included in commercial products. After this phase, the main focus has been addressed to the creation of a re-usable and versatile test of the device after the tape-out which is close to become one of the major cost factor for ICs companies, strongly linking it to model’s test-benches to avoid re-design phases and multi-environment scenarios, producing a very effective approach to a single, fast and reliable multi-level verification environment. All these works generated different publications in scientific literature. The compound scenario concerning the development of sensor systems is presented in Chapter 1, together with an overview of the related market with a particular focus on the latest MEMS and MOEMS technology devices, and their applications in various segments. Chapter 2 introduces the state of the art for sensor interfaces: the generic sensor interface concept (based on sharing the same electronics among similar applications achieving cost saving at the expense of area and performance loss) versus the Platform Based Design methodology, which overcomes the drawbacks of the classic solution by keeping the generality at the highest design layers and customizing the platform for a target sensor achieving optimized performances. An evolution of Platform Based Design achieved by implementation into silicon of the ISIF (Intelligent Sensor InterFace) platform is therefore presented. ISIF is a highly configurable mixed-signal chip which allows designers to perform an effective design space exploration and to evaluate directly on silicon the system performances avoiding the critical and time consuming analysis required by standard platform based approach. In chapter 3 we describe the design of a smart sensor interface for conditioning next generation MOEMS. The adoption of a new, high performance and high integrated technology allow us to integrate not only a versatile platform but also a powerful ARM processor and various IPs providing the possibility to use the platform not only as a conditioning platform but also as a processing unit for the application. In this chapter a description of the various blocks is given, with a particular emphasis on the IP developed in order to grant the highest grade of flexibility with the minimum area occupation. The architectural space evaluation and the application prototyping with ISIF has enabled an effective, rapid and low risk development of a new high performance platform achieving a flexible sensor system for MEMS and MOEMS monitoring and conditioning. The platform has been design to cover very challenging test-benches, like a laser-based projector device. In this way the platform will not only be able to effectively handle the sensor but also all the system that can be built around it, reducing the needed for further electronics and resulting in an efficient test bench for the algorithm developed to drive the system. The high costs in ASIC development are mainly related to re-design phases because of missing complete top-level tests. Analog and digital parts design flows are separately verified. Starting from these considerations, in the last chapter a complete test environment for complex mixed-signal chips is presented. A semi-automatic VHDL-AMS flow to provide totally matching top-level is described and then, an evolution for fast self-checking test development for both model and real chip verification is proposed. By the introduction of a Python interface, the designer can easily perform interactive tests to cover all the features verification (e.g. calibration and trimming) into the design phase and check them all with the same environment on the real chip after the tape-out. This strategy has been tested on a consumer 3D-gyro for consumer application, in collaboration with SensorDynamics AG

Design of electronic systems for automotive sensor conditioning

This thesis deals with the development of sensor systems for automotive, mainly targeting the exploitation of the new generation of Micro Electro-Mechanical Sensors (MEMS), which achieve a dramatic reduction of area and power consumption but at the same time require more complexity in the sensor conditioning interface. Several issues concerning the development of automotive ASICs are presented, together with an overview of automotive electronics market and its main sensor applications. The state of the art for sensor interfaces design (the generic sensor interface concept), consists in sharing the same electronics among similar sensor applications, thus saving cost and time-to-market but also implementing a sub-optimal system with area and power overheads. A Platform Based Design methodology is proposed to overcome the limitations of generic sensor interfaces, by keeping the platform generality at the highest design layers and pursuing the maximum optimization and performances in the platform customization for a specific sensor. A complete design flow is presented (up to the ASIC implementation for gyro sensor conditioning), together with examples regarding IP development for reuse and low power optimization of third party designs. A further evolution of Platform Based Design has been achieved by means of implementation into silicon of the ISIF (Intelligent Sensor InterFace) platform. ISIF is a highly programmable mixed-signal chip which allows a substantial reduction of design space exploration time, as it can implement in a short time a wide class of sensor conditioning architectures. Thus it lets the designers evaluate directly on silicon the impact of different architectural choices, as well as perform feasibility studies, sensor evaluations and accurate estimation of the resulting dedicated ASIC performances. Several case studies regarding fast prototyping possibilities with ISIF are presented: a magneto-resistive position sensor, a biosensor (which produces pA currents in presence of surface chemical reactions) and two capacitive inertial sensors, a gyro and a low-g YZ accelerometer. The accelerometer interface has also been implemented in miniboards of about 3 cm2 (with ISIF and sensor dies bonded together) and a series of automatic trimming and characterization procedures have been developed in order to evaluate sensor and interface behaviour over the automotive temperature range, providing a valuable feedback for the implementation of a dedicated accelerometer interface

Low-cost autonomous 3-D monitoring systems for hydraulic engineering environments and applications with limited accuracy requirements

The details of developing autonomous 3-D motion monitoring systems based on commercial off-the-shelf (COTS) motion sensors for hydraulic environments are discussed. Possible areas of application, are river bed sediment transport monitoring and monitoring the agitation and other physical parameters inside milk vats with a mechanized agitator. Simplified calculations of inertial navigation systems (INSs) such as Euler angle method, MATLAB programs for further processing, power management systems for autonomous operation including the possibility of inductive power transfer (IPT) and use of microelectromechanical systems (MEMS) technology are discussed. Experimental results for proof of concept systems are highlighted

Velocity measurement based on inertial measuring unit

Vehicles technology have been a priority area of research over the last few decades. With the increasing the use of electronic components in the automotive industry to measure conditions around the vehicle, the focus of automotive technology development is now leading to the development of active technology. Information on the speed of conventional vehicles is generally still obtained based on the rotation of the wheel, but there are weakness in the system that is the diference between wheel and road through vehicle also changes wheel radius of the vehicle due to wind tube air preasure that can change at any time. In this research used Inertial Measuring Unit (IMU) 6 axis (accelerometer and gyroscope) which have been done filtering by using Kalman filter in order to make output sensor value more stable, results obtained at the test of 0 m/s had an RMS error of 0.8696 m/s when elevation is +450; 0.0393 m/s when elevation is 00; and 0.3030 m/s when elevation is -450. this research is expected to be an exploration for the development of a decent system that is suitable to be used as vehicle speed estimator which is as reliable as it is by using an existing speedometer on a ground vehicle generally regardless of slippage and changes in wind capacity on wheels

Automotive Suspension Parameter Estimation Using Smart Wireless Sensor Technology

This thesis project demonstrates the feasibility of using a smart sensor system to estimate vehicle parameters. It includes the development of the smart sensor system and the method for which vehicle parameters are estimated using this system. The smart sensor system is a wireless computer controlled sensor array that can be easily installed onto a vehicle. Parameter estimation was accomplished using grey box code in Matlab System Identification Toolbox, a software package from Mathworks. Front and rear suspension damping rates and pitch inertia were estimated on the 2008 Cal Poly SAE Baja Car with good accuracy during testing

Vibration Analysis of Modern Fire Apparatus

A purpose-built, novel sensor was developed to facilitate vibration recording of modern fire apparatus. A front-end recording virtual instrument was developed using the National Instruments LabView suite. A second virtual instrument was designed to normalize the data to standard gravity and to characterize its spectral content. Preliminary baseline tests showed that the low-cost sensor provided adequate signal to noise ratios. Vibration characterization of pumper apparatus revealed pump induced vibrations were in excess of 0.26 g. Documentation and instructions on the operation of the sensor are contained herein for usage in subsequent vibration recording of fire apparatus