Monitoring of multiple-electrode gas sensors

• US 5,789,659 A
• Filed: 02/05/1996
• Issued: 08/04/1998
• Est. Priority Date: 08/05/1993
• Status: Expired due to Term

• Current Assignee: Life Safety Distribution AG (Honeywell International Inc.)
• Original Assignee: Capteur Sensors & Analysers Ltd. (Honeywell International Inc.)
• Inventors: Williams, David Edward
• Primary Examiner(s): Williams, Hezron E.
• Assistant Examiner(s): WIGGINS, JOHN DAVID
• Application Number:
  US08/592,407
• Time in Patent Office: 911 Days
• Field of Search: 73/23.2, 73/23.21, 73/24.04, 73/31.06, 73/335.05, 340/632, 340/634, 204/412, 204/411, 364/498, 364/553, 364/576
• US Class Current: 73/23.2
• CPC Class Codes: G01N 27/12 of a solid body in dependence upon absorption of a fluid; of a solid body in dependence upon reaction with a fluid , for detecting components in the fluid
• CPC Class Codes: G01N 33/0031 comprising two or more sensors, e.g. a sensor array
• CPC Class Codes: G01N 33/007 Arrangements to check the analyser calibrating gas analysers G01N33/0006

Abstract

A gas sensor, suitable for use under non-steady state conditions, has a gas-sensitive resistor with pairs of electrodes which either have different spacings between the electrodes of a pair, or comprise a pair at the active surface and further pairs buried in the resistor at different distances from the active surface. The sensor can be used in place of a sensor array, and is coupled to a processor for processing the resistance signals to detect and/or measure at least one target gas. The sensor is self-diagnostic, and factors such as relative humidity and ambient oxygen, that can otherwise affect the readings, can be compensated for without the aid of additional sensors for that purpose. An operating line or surface is defined for the expected behavior of the sensor, and the resistance signals from the electrode pairs are processed so at to give information which is then related to the operating line or surface, so as to reveal, in terms of error indications, any malfunction of the sensor and/or the presence of specific constituents of the gas mixture.

Claims

1. A method of analysing a gaseous medium using a multiple-electrode resistive gas sensor of solid state semiconductor material comprising a resistor having an active surface and a plurality of pairs of electrodes, disposed on said resistor, each pair of said plurality of pairs of electrodes being different from each other pair of said plurality of pairs of electrodes as regards the spacing between the electrodes of the pair or the geometric orientation and disposition of the pair within the resistor relative to the active surface, the gaseous medium containing at least one target gas capable of causing electrical resistance of the sensor to vary in response to concentration of that gas, the method comprising:

taking a resistance signal from each electrode pair with the sensor exposed to the gaseous medium;

processing the signals to produce measurements therefrom; and

relating the said measurements to a defined operating line or surface so as to determine, by deduction therefrom, a plurality of items of information, with the concentration of each target gas to be detected representing a separate said item of information, the number of electrode pairs being at least equal to the number of items of information to be obtained.

2. A method according to claim 1, including the correction of any error arising from the presence in the gaseous medium of a constituent that alters the sensor response, wherein each such error represents one item of information of said plurality of items of information to be obtained, so that the number of electrode pairs is at least equal to the number of target gases to be determined plus the number of said errors to be corrected for in said sensor response.

3. A method according to claim 2, including the step of deducing from the relationship between the said measurements and the defined operating line or surface a said error comprising a shift from the defined operating line or surface due to water vapour and/or ambient oxygen partial pressure in the said medium, the processing step including applying a correction to compensate for the relative humidity and/or ambient oxygen in the said medium and/or measurement thereof.

4. A method according to claim 1, including the step of deducing from the relationship between measurements and the defined operating line or surface a said error resulting from malfunction of the sensors, whereby the monitoring of the sensor comprises testing the sensor itself.

12. A method according to claim 1, wherein the signal processing step includes:

processing first signals from a primary electrode pair;

processing second signals from at least one secondary electrode pair; and

computing the delay between the said first and second signals.

13. A method according to claim 12, wherein each signal is analysed into a set of sinusoidal variations, the delay being measured by computing from the said variations a transfer function for the or each secondary electrode pair relative to the primary electrode pair, the operating line or surface being defined at least partly in terms of the transfer functions.

14. A method according to claim 13, wherein the operating surface is defined as the expected variation of the amplitude and phase of the transfer functions of the different electrode pairs, as a function of frequency of variation in gas concentration to which the sensor is exposed.

15. A method according to claim 12, wherein a cross-correlation function is defined between the said first and second signals, the or each secondary electrode pair having a characteristic value of the said delay which is characteristic of that electrode pair, the cross-correlation function having a maximum value at the or each said characteristic value, the operating line or surface being defined at least partly in terms of the said characteristic value or values.

16. A method according to claim 12, wherein the signal processing step comprises measuring hysteresis between the said signals from different electrode pairs, the operating line or surface being defined by the magnitude of an extreme hysteresis value generated on at least one electrode pair as a function of an extreme value of the resistance signal from one electrode pair, so that an error resulting from sensor malfunction can be deduced from the relationship between the said measurements and the defined operating line or surface, whereby to test the sensor itself.

17. A method according to claim 16, for a sensor having a primary electrode pair and a plurality of secondary electrode pairs, wherein the operating surface is defined by the values of an extreme hysteresis value generated on each secondary electrode pair between the resistance signal from that pair and that from the primary pair, as a function of an extreme value of the resistance signal from the primary pair.

5. A method of monitoring a gas sensor comprising a gas-sensitive resistor of solid state semiconducting material having an active surface and a plurality of pairs of electrodes disposed on said resistor, each pair of said plurality of pairs of electrodes being different from each other pair as regards the spacing between the electrodes of the pair or the geometric orientation and disposition of the pair within the resistor relative to the active surface, the method comprising the steps of:

defining an operating line or operating surface for the operation of the sensor in a gaseous medium at the active surface;

exposing the sensor to a gaseous medium;

processing the signals from each electrode pair that represent the resulting resistance of the resistor between the electrodes of that pair, so as to produce measurements therefrom defining an operating point; and

relating the operating point to the defined operating line or surface, whereby the presence of an error in the detection of at least one gas in the said medium can be deduced from any shift of the operating point with respect to the defined operating line or surface, wherein the operating line or surface is defined for operation under non-steady state conditions, the sensor being exposed to the medium under non-steady or steady state conditions.

6. A method according to claim 5, wherein the signal processing step includes:

processing first signals from a primary electrode pair;

processing second signals from at least one secondary electrode pair; and

computing the delay between the said first and second signals.

7. A method according to claim 6, wherein each signal is analysed into a set of sinusoidal variations, the delay being measured by computing from the said variations a transfer function for the or each secondary electrode relative to the primary electrode pair, the operating line or surface being defined at least partly in terms of the transfer functions.

8. A method according to claim 7, wherein the operating surface is defined as the expected variation of the amplitude and phase of the transfer functions of the different electrode pairs, as a function of frequency of variation in gas concentration to which the sensor is exposed.

9. A method according to claim 6, wherein a cross-correlation function is defined between the said first and second signals, the or each secondary electrode pair having a characteristic value of the said delay which is characteristic of that electrode pair, the cross-correlation function having a maximum value at the or each said characteristic value the operating line or surface being defined at least partly in terms of the said characteristic value or values.

10. A method according to claim 6, further including the step of applying a pulse of gas to the sensor, the signal processing step comprising measuring hysteresis between the said first signals and said second signals, the operating line or surface being defined by the magnitude of an extreme hysteresis value generated on at least one electrode pair as a function of an extreme value of the resistance signal from one electrode pair, so that an error resulting from sensor malfunction can be deduced from the relationship between the said measurements and the defined operating line or surface, whereby to test the sensor itself.

11. A method according to claim 10, for a sensor having a primary electrode and a plurality of secondary electrode pairs, wherein the operating surface is defined by the values of an extreme hysteresis value generated on each secondary electrode pair between the resistance signal from that pair and that from the primary pair, as a function of an extreme value of the resistance signal from the primary pair.