Harald Steiner

Robust Precision Position Detection With an Optical MEMS Hybrid Device

For vibration and displacement sensors, robustness is one of the key requirements. Optical measurement concepts are among the most promising possibilities to achieve it. The presented microoptoelectromechanical system sensor modulates a light flux by means of two congruently placed aperture gratings: one etched into a seismic mass and the other fixed to the sensor package. Commercially available LED and photodetector components at the top and bottom of the sandwich structure generate and detect this modulated light flux and allow for a cost-effective implementation. The prototype used for experimental verification is actuated by inertial forces and exhibits a high sensitivity of 0.85 mV/nm for displacements of the seismic mass and a corresponding noise level of about 14 pm/√Hz. This sensitivity and noise level can be further improved, paving the way for small, lightweight, robust, and high-precision displacement sensors for a large variety of applications.

An Optical In-Plane MEMS Vibration Sensor

This paper presents encouraging results of a novel optoelectronic conversion method for relative displacement. An optical modulator responding to acceleration and gravitation is used for characterization. The Si microelectromechanical system (MEMS) component comprise a spring suspended, in-plane oscillating mass carrying an array of optical apertures. Light flux modulation is achieved with a second array of complementary apertures that is fixed to the Si frame. The investigated device comprises a sandwich structure of an SMD LED, the MEMS aperture gratings, and a phototransistor. Relative displacements of the gratings generate a modulation of the LED light flux that is detected by the phototransistor. Depending on the aperture design, the relative displacement may extend over several tens of microns maintaining a sub-nm resolution. Thus, no closed-loop position control system is required, resulting in minimum complexity and energy consumption of the MEMS component. This setup simplifies the manufacturing process as much as possible, which is one of the significant advantages of the sensor principle. Furthermore, the presented prototype exhibits a promising high sensitivity of 60 nA/nm for displacement, featuring a noise level of about 8 pm/√Hz.

Planar Magnetostrictive Micromechanical Actuator

A magnetostrictive actuator approach based on micromechanical structures is presented. Planar geometries are designed, comprising V-shaped beams and lever transmissions. Several V-shaped beams are stacked in parallel and two of such stacks are placed facing each other. Both are connected to a lever beam. When a magnetic field is applied, the magnetostriction of the active material leads to an elongation/shortening of the V-shaped beams. The lever transmission converts the magnetically induced elastic energy into a reliable in-plane displacement. The overall dimensions of the devices are in the range of 4 mm × 2 mm × 0.4 mm and hence, way smaller compared with state-of-the-art magnetostrictive actuators. For a magnetic flux density of 14 mT, a stroke displacement of 10.2 μm was achieved. With a spring stiffness of 5.56 N/m obtained from simulations, a theoretical area specific work of 72 μJ/m2 was accomplished.

A miniaturized linear shaker system for MEMS sensor characterization

A miniaturised, piezoelectrically driven shaker system is presented which is suitable for MEMS characterisation in vacuum. It offers a broad frequency and amplitude range. The fully vacuum compatible shaker is constructed out of one single peace of aluminium with a piezo-stack-actuator working in-plane against four beam springs. It can easily be fabricated at low costs using a hand operated milling machine. The systems characteristics are easily tuned to different applications as the first resonance frequency is given by the stiffness of the beam springs and the mass of the moving shaker table. The utilised piezoelectric stack determines the maximum reachable amplitude for a given spring stiffness. Finite Element simulations have been carried out to design a at transfer characteristic of the shaker up to 10 kHz and amplitudes in the range from sub nanometres up to 1μm. The simulations were evaluated by laser vibrometer measurements of the shaker which also show a good linearity between electrical excitation signal and output deection amplitude. To account for other resonance frequencies introduced by a preexisting MEMS mounting device, the resulting vibration amplitude on the MEMS structure can be normalised by adjusting the electrical excitation amplitude with the help of a Polytec laser vibrometer.

Towards distributed enthalpy measurement in large-scale air conditioning systems

Air conditioning systems are among the major energy consumers in buildings. Energy-efficient operation of AC systems is an important step towards better energy management in building automation, but requires efficient monitoring of the energy or enthalpy flows within the AC installation, which is currently still difficult because of the lack of appropriate equipment. This paper introduces a distributed data acquisition system for large-scale AC systems based on low-cost flow sensors implemented by means of standard printed circuit board technology and interconnected via a wireless sensor network. A critical issue for the system installation is the placement of the sensors in the air ducts to obtain representative measurements of the air flow. To this end, extensive aerodynamical simulations are carried out to analyze the flow distributions in typical building blocks for air ducts, particularly with respect to turbulences. The simulation results are compared with experimental data from the literature and are shown to be reliable.

Characterization and optimization of a thermal flow sensor on circuit board level

The characterization and optimization of a low-cost thermal flow sensor optimized for the use in heating ventilating and air conditioning (HVAC) systems is presented. The fabrication of the transducer is exclusively based on printed circuit board technology to keep costs low and allow for easy handling and replacement. The measurement principle utilizes a calorimetric principle with thermoresistive heat transfer. The thermistors form a Wheatstone bridge while the heating element is supplied with a constant current. The AC bridge output voltage is a function of the flow offering adequate sensitivity and a suitable measurement range for HVAC systems. The main experiments focus on flow measurements with a Lock-In amplifier technique to evaluate the measurement range and sensitivity. Based on prior results for time constants, output voltage, sensitivity, etc., the sensor design has been optimized.

Highly Efficient Passive Thermal Micro-Actuator

A passive thermal micro-actuator with large area specific work and large displacement, fabricated of electroplated nickel on a silicon substrate is presented. The actuation relies on the thermal expansion of beams in a V-shaped geometry. Two V-shaped beam stacks are aligned opposite to each other and are coupled to a lever transmission. The actuator exhibits low energy losses due to the deformation of the structure and can efficiently convert the thermally induced elastic energy into mechanical work. An analytical model considers these thermally induced mechanical energies and the energy losses caused by the deformation of the material. The calculated deflections are compared with the measured ones and results of finite-element method simulations. The presented actuator operates completely passive, relies only on temperature changes of the surrounding environment, and exhibits a measured temperature-dependent linear deflection coefficient of 1.48 μm/K with a simulated blocking force of 57 μN/K. The structure occupies an area of 2135 × 1831 μm2 and the area specific work is calculated to be 21.7 μJ/K2/m2, beating state of the art thermal actuators. As proof-of-concept, a passive micro-electro-mechanical systems temperature threshold sensor is fabricated, featuring the actuator and a bistable beam that switches between two stable positions when a specific threshold temperature is exceeded.

Thermal flow sensors based on printed circuit board technology

Measurement of air flows is an important task in many process monitoring systems. In applications like control of ventilation and air conditioning systems, robustness, ease of use, and cost are important issues calling for simple and effective sensor design. This paper investigates the use of commercial-off-the-shelf printed circuit board technologies for the fabrication of calorimetric flow sensors. Such sensors are known to be sensitive when being implemented using thin-film technology. The paper reviews the operation principle of thermal flow sensors and their performance in micromachined silicon technology for comparison. Subsequently, a similar design is introduced where heating and temperature sensing elements are made from standard copper traces on a flexible PCB substrate. Simulation studies demonstrate the basic viability of this approach, even if it might entail some performance penalties. First experimental data of sensor prototypes show that the repeatability of the PCB manufacturing processes is basically sufficient for using copper traces as sensors, but leaves also room for future improvement in both technology and sensor design.

MEMS heterodyne AMF detection with capacitive sensing

A Lorentz-force actuated cantilever used as a magnetometer detecting alternating magnetic fields (AMF) is described. The device consists of a U-shaped single-crystal silicon cantilever manufactured in SOI technology. This micromachined cantilever features a length of 2mm, a base width of 90μm, and a thickness of 20μm, whereat the two 2mm cantilevers are hold together by a 1.5mm long bar at the free moving ends. The cantilever is placed in a vacuum chamber surrounded by a pair of coils configured as Helmholtz coil which generates the alternating magnetic field. The test structures are harmonically excited by the Lorentz force acting on the gold lead at the top surface of the cantilever carrying an alternating current. In the presence of a sinusoidal magnetic flux density, the resulting Lorentz force contains two alternating terms including the sum and difference of current and field frequencies. Therefore, the resonating cantilever is used as mixer in a heterodyne detector for alternating magnetic fields with variable frequency. Resonant excitation only occurs if one of these frequencies is close to a mechanical resonance that satisfies the selection rule imposed by the field configuration. In the experiments, emphasis is laid on the investigation of the first symmetric and first antisymmetric vibration mode, where the amplitude of the vibration is proportional to the exciting vector component of the magnetic field. For this work the harmonic deflection of the cantilever was measured with a capacitive readout system and additionally, with a laser-Doppler vibrometer. By changing the drive current, the operating range of the magnetometer can be varied from a few μT up to 1mT, whereas the sensitivity remains constant with an uncertainty of less than one percent, valid for both vibration modes. This operation principle of the prototype allows a further miniaturization leading to a spatial resolution of the magnetic field detection determined by the size of the cantilever.

Design of linear and nonlinear hybrid optical MEMS displacement sensors

Although capacitive and piezoresistive readouts are commonly used for microelectromechanical structures, they suffer from serious drawbacks like limited range of displacement, inherent nonlinearity, insucient sensitivity, and technological complexity. Our complementary readout approach relies on a novel hybrid optomechanical device, where the displacement range is not limited by typical constraints of capacitive or piezoresistive conversion principles. Furthermore, no electrical connections are required on the micromechanical part. Moreover, this principle enables custom linear or nolinear output characteristics at the same technological effort.