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Reliable simulation of sensors

For troubleshooting or commissioning

It is often the case that sensors only provide meaningful signals if the complete system is in operation. If this is not possible or if we do not rely on the sensor signals, a simulator that is quick and easy to connect is an ideal tool. In this manner, the fault can be localised or found, whether the error is due to a fault in the sensors or the control unit.

It can be difficult to test a system that is not completely installed. The signals of the sensors - if they are even connected - can never deliver the correct information. Consequently, servo loops, etc. cannot be tested. In some cases, various tricks can be used to elicit values from the sensors which approximate those from the process, but this is often extremely difficult. Consider the example of temperature regulation of a furnace. Without the furnace, it is difficult to install the sensors to deliver the values expected in the finished system. In this case, it is practical to simulate the sensors with, for example, a variable voltage or current source depending on whether the sensor delivers a voltage or a current as an output signal. It is even more practical to use a SensorSimulator that delivers output signals corresponding to those of the sensors.

A simulator is also a good tool for troubleshooting in a system. With a simulator, you can quickly determine whether the error is in the sensor or in the control unit. For this purpose, it is no longer mandatory that the entire process is in operation. The simulator delivers the sensor signals with which any situation can be easily simulated as a 'dry run'.

Many varieties

A simulator that can simulate all types of sensors is a very helpful tool in practical applications. Unfortunately, that is impossible, because there are now sensors that communicate digitally via bus systems. If we limit ourselves to analogue sensors, the new SIM-1 of GHM GROUP is a device that satisfies most requirements. The block circuit diagram in Figure 1 shows how the device is configured and which sensors it simulates. Figure 2 shows how to connect the simulator in order to simulate the different sensors. This is how the connection is made for strain gauges. Therefore, the simulator also has a 7-pin plug connector (Figure 3).

The SIM-1 SensorSimulator has the same housing as all other portable measuring devices from GHM GROUP. This housing has an IP65 protection rating and a protective rubber casing. Therefore, it can also be used in demanding industrial environments.

Operation is very easy and user-friendly. The device has six buttons on the front side and a large display that shows the settings and values.

Area of application

The device is very well-suited for comparison and checking of displays, sensors and transducers. It is used to check complete systems. In addition to the simulation function for voltages, currents, DMS signals and temperatures (thermocouples of the type K, J, N and S, as well as Pt100), the SIM-1 has a measuring function for voltage (± 30 V) and current (± 30 mA). The device can also be expanded with a frequency sensor. All menus for adjustment of the device can be reached via a clearly arranged key field. The backlit graphic display facilitates operation and makes the simulator an efficient tool that you can take anywhere. The integrated lithium-ion battery provides power for up to eight hours of operation.

Applicable for

• Maintenance and service – Checking error statuses is often a complicated and time-consuming process. Is the error in the measuring devices or in the control unit? With a simulator, the individual elements can be removed from the measuring device and simulated with the SIM-1.

• Problem-solving – Using simulation, you can check step-by-step to determine whether the defect is in the sensor, the wiring or the control unit.

• Commissioning – The SensorSimulator is also a valuable tool for commissioning. For example, it can be used to check very quickly whether the control unit reacts correctly to a specific value of the sensor signal. In this manner, the entire process chain can be simulated in order to test the behaviour of the control unit when interacting with other sensors. For this purpose, various scenarios can be tested with the simulator without testing implementation of the relevant control unit in the real system.

• Validation – For preventive risk control, the SensorSimulator can be used to generate defined values in order to study the reaction of the control unit or the actuator to simulated limit values. As a result, safety standards or quality specifications can be purposefully simulated and checked for compliance.

Details

  • Carl-Benz-Straße 11, 88696 Owingen, Germany
  • GHM GROUP - Imtron