Learn how to test a sensor to ensure it meets required specifications, using common methods and tools. Find tips to improve accuracy, reliability, and efficiency.

I think, the sensor manufacturer will always send out a sensor only after 100 percent testing. They will usually come with certifications for their testing/calibrations. What really matters is whether it really suits the applications we are looking to employ it at. There is no use in testing the sensor at places where it may not perform as per specifications.

Last updated on Jun 14, 2024

How can you test a sensor to ensure it meets required specifications?

Sensors are essential components of modern automotive manufacturing, as they provide vital information and feedback to control systems, engines, safety features, and more. However, sensors also need to be tested to ensure they meet the required specifications and performance standards, as well as to detect any defects or malfunctions. In this article, you will learn how to test a sensor to ensure it meets required specifications, using some common methods and tools.

1 Sensor Specifications

Before you test a sensor, you need to know what specifications it should meet. These may include parameters such as accuracy, range, resolution, response time, linearity, hysteresis, drift, and noise. You can find these specifications in the sensor datasheet, the manufacturer's website, or the application requirements. You should also be aware of the environmental conditions that the sensor will operate in, such as temperature, humidity, vibration, and electromagnetic interference.

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Race Austin

Calibration Tech 2 at MKS Instruments.
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It is important to understand the manufacturing specifications. The manufacturer has standards and processes that define the way the sensors can be ran. As a technician at a manufacturing facility, there are horror stories we hear of customers using our products wrong because they do not do the research required. Doing the research ahead of time reduces defects, downtime, and potential damage of equipment.

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Warlley Oliveira Ferreira

Engenheiro Eletricista | Controle e Automação | Especialista em Eletroeletrônica Automotiva | Hybrid and Electric | Instrutor de Formação Profissional
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Estar atento as especificações para a escolha correta do sensor, irá evitar problemas futuros como leituras incorretas, funcionamento irregular, perda de tempo com diagnósticos e parametrização.

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2 Sensor Testing Methods

Testing a sensor requires different methods, depending on the type of sensor, the output signal, and the equipment available. Calibration involves comparing the sensor output with a known reference value and adjusting it to reduce the error. It can be done with a multimeter, calibrator, or reference sensor. Simulation is applying a simulated input to the sensor and observing the output response, which can be done with a signal generator, simulator, or software program. Lastly, verification verifies that the sensor output meets the specifications and expectations for the application. This can be done using a test bench, test fixture, or test system that provides a controlled and repeatable environment for testing accuracy, range, resolution, response time, linearity, hysteresis, drift, and noise.

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Warlley Oliveira Ferreira

Engenheiro Eletricista | Controle e Automação | Especialista em Eletroeletrônica Automotiva | Hybrid and Electric | Instrutor de Formação Profissional
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Acredito que apenas um multímetro não seja adequado para coletar todos os dados necessários e desejados. Embora seu uso seja crucial, um osciloscópio seria capaz de capturar a curva do sinal produzido pelo sensor. Com isso, seria possível analisar o tempo de resposta, as interferências, a linearidade e o ruído do circuito, entre outros fatores cruciais para um desempenho adequado.

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Race Austin

Calibration Tech 2 at MKS Instruments.
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Testing a sensor against a controlled/"master" setting is vital to obtain accurate information. Sensors can and do drift, and it is important to catch the errors in the equipment early on. Repeatability and standardized testing are one of the most important items for accuracy. Where I am currently employed, we have sensors, master sensors, and master sensors for the master sensors. We store all the data in-house, and have traceability on all sensors we have.

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3 Sensor Testing Tools

Testing a sensor requires tools to connect, measure, and analyze the sensor output. Wires and connectors should be compatible with the sensor type, voltage, current, and frequency. Additionally, they should be secure, clean, and shielded from interference. A power supply should match the sensor specifications and be adjustable and regulated. The testing device should have a high accuracy, precision, and resolution, as well as being suitable for the sensor type, output signal, and range. For data acquisition, you should use a system with a high sampling rate, bandwidth, and memory that can interface with the sensor and testing device. It should also have software to analyze, plot, and export the output data.

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4 Sensor Testing Procedure

To properly test a sensor, you must follow a procedure that ensures the sensor is set up, tested, and evaluated correctly. This may include preparing the sensor by checking for any physical damage, dirt, or corrosion and cleaning if necessary. Connecting it to the power supply, testing device, and data acquisition system with the right wires and connectors. Turning on the power supply to make sure it is operating. Then performing the test by selecting a method like calibration, simulation, or verification and applying the input variable to the sensor with the testing device. Monitoring the output with the data acquisition system and recording any data. Evaluating the results by analyzing the output data with the software and comparing it to specifications and expectations. Calculating any errors or deviations in the output and determining if it meets standards. Identifying any issues or problems with performance and troubleshooting if possible.

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Warlley Oliveira Ferreira

Engenheiro Eletricista | Controle e Automação | Especialista em Eletroeletrônica Automotiva | Hybrid and Electric | Instrutor de Formação Profissional
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Em um teste de sensores em veículos, inicialmente verificamos a ausência de comunicação ou DTCs gerados (via software). Em seguida, examinamos a integridade do sensor, sua alimentação elétrica e sinal gerado. Conforme os resultados obtidos, prosseguimos para o diagnóstico do sensor ou do circuito. A verificação das especificações de montagem, calibração e características operacionais é fundamental para auxiliar no diagnóstico e nos testes de bancada.

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Fethi JARRAY

Supplier Project Quality Leader at SOMFY Group
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The best method to test a sensor is to simulate the defect which are dedicated to detect, for example if you have a sensor to detect and accept only red color, you can test if the sensor detecting as defect the other color possible to pass in front of him. In some cases and types of sensors it is possible to test sensors by SW

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5 Sensor Testing Tips

In order to test a sensor effectively, it is important to follow some tips that can help improve accuracy, reliability, and efficiency. This includes following the manufacturer's instructions and recommendations for the sensor testing, using a calibrated and verified testing device, and using a stable power supply. Additionally, shielded and twisted wires and connectors should be used to avoid loose or faulty connections. Furthermore, a suitable data acquisition system should be used and adjusted according to the sensor output signal and range. Lastly, it is important to use a controlled and repeatable environment for the sensor testing while also documenting the procedure, results, and analysis.

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Race Austin

Calibration Tech 2 at MKS Instruments.
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It is vital to test a sensor effectively, this includes variability. For example, if two different technicians are testing the same sensor, there could be a lot of room for error. It is important to have standards in place to remove as much variation as possible. Now, it is also important to do multiple tests in different environments as well. The law large numbers of states that the more often a test is run, the more accurate the data will be. Testing the sensor regularly, in a controlled setting will produce the greatest, most accurate results.

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6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Rohan Bhojannawar

Product Manager | Automation Robotics | Computer Vision
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I think, the sensor manufacturer will always send out a sensor only after 100 percent testing. They will usually come with certifications for their testing/calibrations. What really matters is whether it really suits the applications we are looking to employ it at. There is no use in testing the sensor at places where it may not perform as per specifications.

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How can you test a sensor to ensure it meets required specifications?

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1 Sensor Specifications

2 Sensor Testing Methods

3 Sensor Testing Tools

4 Sensor Testing Procedure

5 Sensor Testing Tips

6 Here’s what else to consider

Automotive Manufacturing

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