Development of automatic verification/calibration system for temperature and humidity test equipment

**Development of Automatic Verification/Calibration System for Temperature and Humidity Test Equipment** The calibration of temperature and humidity test equipment is an important measurement and calibration project that has developed rapidly in the past decade. It serves as a vital source of income for many thermal or physical and chemical professions. Due to the heavy workload and complex data processing, we began developing the automatic verification/calibration system for temperature and humidity test equipment in 1997. After years of continuous upgrades in both hardware and software, we have gradually accumulated experience and knowledge, which we now share with everyone here, hoping to assist in the development of similar automatic verification systems. **First, the composition of the system** An automatic verification/calibration data acquisition system consists of a temperature sensor, a humidity sensor, a laptop (PDA or smartphone), as shown in Figure 1. Automatic verification systems can be connected via RS-232 or USB port of a laptop computer, or via wireless Bluetooth or other communication methods to connect with a smartphone (or PDA), offering convenience and flexibility. With the widespread use of smartphones, it has become increasingly convenient and popular to use them as data displays, recorders, and processors. Data collectors can be stacked according to user requirements to meet the measurement needs of dozens of channels. **Second, the problems and solutions solved by the software and hardware systems:** 1) **Visually reflecting the performance of the calibrated device:** To visually reflect the initial performance of the calibrated equipment, we use real-time curve drawing, which intuitively reflects the temperature and humidity fluctuations of the calibrated equipment. According to the degree of dispersion of the curve, the uniformity of the calibrated equipment can be visually reflected. The curves for each channel are marked in different colors and can be changed at any time. The system has designed up to 20 curves to meet the recording requirements of multi-channel temperature and humidity curves. 2) **Correction of sensors and data collectors:** In the automatic detection system, we typically use Class A Pt100 or Pt1000 platinum resistance temperature sensing elements. However, even in class A platinum resistance, there may be errors. Therefore, it is necessary to correct the sensor and meter in the automatic detection system. | Industrial Platinum Thermal Resistance Level | Measuring Range | Standard Resistance Value | Temperature Tolerance (°C) | |---------------------------------------------|------------------------|----------------------------|----------------------------| | Class A | -200°C ~ 850°C | 100Ω | ±(0.15 + 0.002|t|) | | Class B | -200°C ~ 850°C | 100Ω | ±(0.30 + 0.005|t|) | When sending the automatic verification system, we usually calibrate the sensor and the overall instrument. In the system software, we designed the “system automatic calibration module” to automatically calibrate the system. When calibrating, the sensor is placed in the water tank or oil tank. After the temperature is balanced, the system automatically reads all the sensor values and inputs the actual value of the standard. The temperature point is calibrated, and the system automatically generates correction values at different temperatures and stores them in the database. During the detection process, the automatic verification system will automatically call and calculate the correction value at the current temperature according to the sensor number, ensuring the accuracy and reliability of the automatic verification result. 3) **Original record and certificate automatically generated:** The automatic verification system can automatically generate original records and certificates that meet the laboratory's approval requirements. However, since each unit's certificate format and information content differ, we adjust the way we use the database so that users can modify the original record and certificate formats as needed. 4) **Problems with accurate measurement of relative humidity:** Temperature measurement techniques are relatively mature, but there are often issues in the field of relative humidity measurement. We used the dry and wet bulb method in the early days, but this approach had limitations. After careful selection, we chose temperature and humidity sensors imported from abroad, which offer better accuracy and avoid A/D conversion errors. 5) **Accurate measurement of the temperature of the cold junction of the thermocouple:** We use four-wire Pt100 as the sensor, ensuring high accuracy. A sealed constant temperature zone is designed at the terminal of the temperature data collector to ensure stable cold junction temperature. This design reduces the impact of ambient temperature and improves measurement accuracy. 6) **How to connect the sensor conveniently and quickly:** After years of selection, we have used two connection methods: one using a standard connector and another using a 12-core quick connector. These methods improve on-site inspection efficiency and make it easier to find and replace damaged sensors. 7) **The problem of the on-site sensor being difficult to clean up:** To solve this issue, we custom-made three-color four-core wires for high-temperature environments. These wires are easier to clean because the lines of each sensor are not scattered. Using a 12-pin quick connector also makes it easier to pack multiple sensors on one plug. 8) **Other problems solved by the software and hardware system:** The software system uses a database to store calibrated equipment information, reducing input workload. The system can simultaneously depict the curves of multiple devices and perform calibrations without interference. It also includes delay (timed) automatic detection and automatic loop detection features. Additionally, the system includes a charging circuit powered by a rechargeable battery, allowing operation for over 24 hours without external power. We have also developed a plastic mold for the data acquisition device, making it lightweight, portable, and vibration-resistant. **Third, the application of the system:** The purpose of the automatic verification/calibration system is mainly for constant temperature and humidity chambers, high and low temperature test chambers, drying ovens, incubators, cement curing boxes, water baths, refrigerators, cold storage, box resistance furnaces, high-temperature carbon furnaces, etc. Since the system is a multi-channel high-precision temperature and humidity data acquisition and processing system, it can also be applied to research and development data collection, GMP certification, and temperature rise experiments in electrical and electronic industries. **Fourth, the conclusion:** Compared with similar automatic detection systems at home and abroad, our system has the characteristics of small size, light weight, and good stability. Due to the developers' extensive on-site inspection experience, the software system has a friendly interface and meets the characteristics of on-site testing. Many valuable opinions were provided during the development and improvement of the system. Thank you.

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