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The design of a sensor circuit is highly individualized, with multiple possible implementation approaches. While the exact method may vary, there are several common steps and considerations in the process. Here's a detailed overview:
First, define the design task by analyzing the type and output characteristics of the sensor, as well as the input requirements of the following circuits and the intended operating environment. Based on this, determine the functions the circuit must perform and the technical specifications it must meet—such as signal conversion, gain, accuracy, dynamic response, size, stability, and reliability.
Next, decide on the circuit structure. This involves choosing between single-ended or differential inputs and determining how the circuit will be divided into functional blocks. Typically, the main circuit is designed first, followed by any additional features. A block diagram is then created to guide the detailed design of each section.
After that, distribute errors across the circuit based on its total accuracy requirement. The distribution should consider the difficulty and cost of achieving high precision. Components that are easier to make accurate get smaller error tolerances, while those that are harder or more expensive receive larger allocations. Once assigned, these errors are combined to ensure they do not exceed the total allowable error.
Then, estimate component parameters. This includes calculating the required gain, resistor values, capacitor values, and other critical parameters for each part of the circuit. Each component must meet specific performance criteria to ensure the overall system works as intended.
Designing for electromagnetic and temperature immunity is also crucial. To enhance the circuit’s reliability and stability, measures such as shielding, filtering, and thermal compensation should be incorporated.
Selecting components comes next. Based on the parameter estimates and performance goals, choose parts with appropriate specifications, grades, and manufacturers. A full list of components should be prepared for reference.
Once the components are selected, assemble the circuit. The assembly can follow a top-down or bottom-up approach, but it should be done step-by-step. If a section works correctly, proceed to the next. This helps identify and resolve issues early, improving efficiency.
After assembly, conduct performance tests. Gather sufficient data for statistical analysis, and test under conditions that simulate real-world environments—such as extreme temperatures, electromagnetic interference, and vibration. Compare the results with the original design specifications.
If the circuit does not meet all requirements, improvements are necessary. Modify the design, retest, and continue refining until the desired performance is achieved.
Finally, create a PCB layout. Once the circuit meets all design goals, prepare the schematics, design the printed circuit board, and mount the components to produce a functional prototype. This completes the design and development cycle.