Test-Measurement (Page 5)

Here is a Millivolt Source i built for Calibration in the early days. It uses only CMOS Digital and Mixed Chips from Intersil and CD40xx Series.

Millivolt Source

Later i tried a unit with 8748 part of the code in my uC section. This is with Ramp-up and Ramp-down using only two buttons. This works even now, The support below is an HRC Fuse Holder made of Phenolic or Epoxy Resin. The mV Terminations are on Top.

This is a LED Analog Meter, This can be used as a Resistance Meter and Low Impedance Voltmeter for Battery Levels. To measure battery voltage, the R5-R12-R17 etc. part of the Reference Resistor Divider Network can be modified to suit. Shown here is for 4 LEDs, Use Three LM324 for 12 or More LEDs and Cascade as shown.

Resistance Measurement Analog LED Meter

This cannot Measure Voltage levels from High Impedance Sources, will work for Battery Voltage Tests. To make it into a Continuity tester. R27 must be a short and R23 5 Ohms. The Black probe should have a Built in Resistance of 2 Ohms. If you want it to be a dedicated voltmeter, remove R3, The Probe has to be a 10X Attenuator with 10M Ohm and The Resistor Divider Steps in 100mV per Step. The R27, R23 etc. is 20K. A Leakage Tester a Mains Voltage Monitor are other possibilities. Use LM3914 for a easier solution. A nice book for your Design Library – Measuring Circuits By Rudolf F. Graf

This is easy to rig millivolt source for field calibration or troubleshooting of 4-20 mA current loops. Here a Darlington pair is used for current amplification which reduces the Ib error as gain is very high.

Millivolt Source - Field Callibration Current Loop

A rotary switch selects, 4-12-20 mA Preset points. A Bourns multi-turn wirewound Pot can also be used with a digital dial. Enclose in a dust proof handheld box. Read more on process calibration.

Here is a current source you can build for resistance measurement. When the current is held constant, you know as per Ohm’s Law the Voltage across Resistor is proportional to Resistance value.

Precision Current Source for Resistance Measurement

The supply is +12 and -12, The total voltage across R6 + R7 is 24V. Then 24V / 120K = 0.2mA. The voltage across R6 is (10K * 0.2mA) = 2V. The same is reflected across R5 in this feedback configuration. That means Q3 is a 2V / 1K = 2mA source. If my calculations are right.

There are sources of errors in this circuit. The temperature variation of all resistor values, which is 100ppm for general calculations in 1% MFR. Let us assume you use OP07 which is close to an ideal opamp, but for this application it is not needed. The second error is Ib, the base current of Q3 which may be 0.2mA / Hfe(200) = ~ 1 uA. Then the variation of Hfe, Vcc and Vdd w.r.t. Temperature, should not be overlooked. Use LM7812 and LM7912.

So you see, design knowing that all these components are not ideal. Leakage currents, Humidity, EMI, Stray Capacitance and Inductance and much more. It is just like, even when the motor is fixed firmly on the machine, some parts Vibrate and create a Noise due to Mechanical Resonance. So Build and evaluate your design in the real environment, to learn.

Discover how resistors are color coded – Interactive Java Resistors Tutorial.

Measurement of resistor values in circuit configurations are required to be made often, as these might have changed in value due to various tolerance ranges, and hence could be the cause of faults. Likewise the resistance of components used in a circuit, may need to be known. In such cases the measurement of resistance is a must.

Simple Resistance Measurement

The circuit used for measurement of voltage can be modified to measure the value of the unknown resistance. The principle followed is the measurement of voltage drop across the resistance when a constant current flows through it. In the voltage measuring circuit, the unknown resistance is connected to the same input terminals and the switch SR is operated. Then a constant d.c. current from the collector of transistor T I is passed through resistor R16 to the unknown resistance which is grounded. The voltage drop across the unknown resistor is proportional to the value of the resistance as current is maintained constant. This d.c. voltage drop is measured after proper calibration.

For the constant current source a high gain, low leakage, pnp silicon transistor (T1) is required. The range selector switch Rs, which connects the positive voltage to the constant current source enables measurement of resistances in 5 decades i.e. 200 ohms, 2 kilo-ohms, 20 kilo-ohms, 200 kilo-ohms and 2 mega-ohms.

According to the range of resistance being measured the switch Rs also selects the decimal point of the displays in the DPM. A resistor R limits the current to the decimal point of the LED displays. Transistor T I is biased by resistor R17 and variable present VR5. As this preset sets the value of current in transistor T1, it has to be adjusted for calibrating the resistance range. Once the calibration is over, the resistance value is directly read on the DPM.

(This is scanned-ocr from my earlier file, some mistakes corrected – delabs)

Studying current measurement is a prerequisite for many of the measuring techniques. The current parameter mainly specifies the power consumption in a circuit, given the value of resistance. It is found convenient to measure current rather than voltage for knowing power output and determining efficiency. It may be required to measure leakages in circuits at certain times. Hence the measurement of current constitutes a priority.

Ammeter and Precision Rectifier

Measurement of DC Current –

The circuit diagram for the measurement of current (d.c. and a.c. modes) is shown aside. For measurement of current switch SI is operated. The switch S-ad is kept in d.c. mode. This enables the current to pass through a shunt circuit consisting of resistors R26, R27, R28, R29 and R 30. The current ranges are provided in 5 decades i.e. 200 micro-amps, 2 milli-amps, 20 milli-amps, 200 milli-amps and 2 amps. An additional current range that can be read upto 20 Amps is also provided. However, for measuring this high current the green terminal provided on the meter should be used. When a current to be measured is fed to the input terminals of the instrument appropriately, a voltage proportional to the current through the shunt resistor is fed into the DPM which measures the d.c. voltage which in turn indicates the d.c. current being fed.

Measurement of AC Current –

In case of a.c. measurement, the switch S-ad is kept in a.c. mode. The a.c. current path is similar to the d.c. current path in the shunt resistor. However the voltage tapped across the shunt resistor is fed into IC2 which is a buffer. The output of IC2 is fed to IC3 through capacitors C10 and C11. This IC is an operational amplifier acting as a precision rectifier. The output of IC3 is fed to the input of the DPM for measuring the a.c. current being fed to the input terminals. It can be seen that the current measurement is similar to the voltage measurement except that the attenuator chain is replaced by the shunt resistor circuit.

(This is scanned-ocr from my earlier file, some mistakes corrected – delabs)

This was a Beta Hfe and Vce Measuring Instrument used in Incoming Inspection of Power Transistors made by me 16 years back.

Transistor Beta Tester

Custom Built Test Instruments

I designed and built many custom “engineered” Test Instruments. They were not prefect, as only one or two were fabricated. That means it will be costly to produce such instruments. It is just like tooling, you have to make some numbers to recover costs, or price it very high to compensate for the wastages and iterations.