Case Studies

Variable Resistor Symbol

High Channel Count Thermistor Simulation

Posted in Aerospace, Automotive, Battery Pack Test Systems, Embedded Development & Programming, Energy and Utilities, Green Technology, Test & Measurement Automation, Test and Measurement

Summary

As one component of a Client's complete test system solution, DMC was required to design and assemble a 50 channel temperature sensor simulator.  The resulting system is capable of simulating a collection of thermistor-based temperature sensors with 8-bit precision and 1% accuracy with 600V isolation between channels.

Relay - Resistor Chain

Relay - Resistor Chain

Thermistor Simulator System

Thermistor Simulator

Thermistor Simulator

Thermistor Simulator

Solution

The design phase of this project started with a search for existing commercial solutions for thermistor simulation.  Despite working with several hardware vendors to find an affordable solution, DMC was unable to find a system meeting the application requirements within the program budget. 

As a result, DMC leveraged its printed circuit board (PCB) design and development expertise to manufacture several custom printed circuit boards to provide the required performance within the Client’s budget. These PCBs were assembled in a 19" rack mount enclosure to provide a single, compact and integrated thermistor simulation solution for the Client’s overall data acquisition system.

Overall this custom component approach saved our Client time, complexity, and costs over available off the shelf solutions.

Customer Benefits

  • Lower Hardware Costs -- versus off-the-shelf solutions, especially for repeat systems.
  • Compact Size -- afforded by integrating signal routing and relays on a single PCB.
  • Improved Performance  -- by providing the required 600V isolation into the design.
  • Shorter Lead Time -- compared to commercial solutions with 4-6 week delivery times.
  • Flexibility -- Range and resolution of simulated outputs are easily modified by swapping daughter cards.

Technologies