1.1 Introduction:The measurement of displacement,position, or location is an important topic in the industry.

Examples of industrial requirements to measure these variables are many and varied, and the required sensors are also of greatly varied designs. To give a few examples of measurement needs: (1) location and position of objects on a conveyor system, (2) orientation of steel plates in a rolling mill., (3) liquid/solid level measurements, (4) location and position of work piece in automatic milling operations, and (5) conversion of pressure to a physical displacement that is measured to indicate pressure. In the following sections, the basic principles of several common types of displacement, position, and location sensors are given:i)Potentiometric ii)Capacitive & Inductive iii)Variable Reluctance iv)Level Sensor

Function of Power Cylinder

Power Cylinder is a linear actuator consisting of a piston in a cylinder, driven by pneumatic or hydraulic fluid under high pressure.Power cylinders, either pneumatically or hydraulically actuated ,find many applications in modern industries.For example ,in a burner management system of a fossil-fuel fired furnace of a thermal power plant,flow of air through different burners is operated by means of power cylinder.The position of the piston inside the power cylinder is mechanically fed back to the position control system of the cylinder by a mechanical cam arrangement with the pistonrod.

1.2 Classification of Position Measurement:PotentiometricThe simplest type of displacement sensor involves the action of displacement in moving the wiper of a potentiometer. This device then converts linear or angular motion into a changing resistance that may be converted directly to voltage and/ or current signals. Such potentiometric devices often suffer from the obvious problems of mechanical wear, friction in the wiper action, limited resolution in wire-wound units, and high electronic noise.

Capacitive and InductiveA second class of sensors for displacement measurement involves change in capacity or inductance.

Capacitive :The basic operation of a capacitive sensor can be seen from the familiar equation for a parallel-plate capacitor

where K = the dielectric constant o =permittivity = 8.85 pF/m A = plate common area d = plate separation

Inductive :If a permeable core is inserted into an inductor the net inductance is increased. Every new position of the core produces a different inductance. In this fashion, the inductor and movable core assembly may be used as a displacement sensor. An ac bridge or other active electronic circuit sensitive to inductance then may be employed for signal conditioning.

Variable ReluctanceThe class of variable-reluctance displacement sensors differs from the inductive in that a moving core is used to vary the magnetic flux coupling between two or more coils, rather than changing an individual inductance. Such devices find application in many circumstances for the measure of both translational and angular displacements. Many configurations of this device exist, but the most common and extensively used is called a linear variable differential transformer (LVDT).

Level SensorsThe measurement of solid or liquid level calls for a special class of displacement sensors. The level measured is most commonly associated with material in a tank or hopper.

1.3 Some Recent Works on Position Measurement:i) Investigation to Commercialize A Power Cylinder which combines Ball Screw and Hydraulic Pressure:A power cylinder is usually used on the industrial design as metal forming, die casting and injection molding process. Generally, power cylinder mechanism has a ball screw or hydraulic cylinder type. This is obtained a high power. That is obtained point to Point control. Therefore, in this present study, the design of a power cylinder, which combines a ball screw mechanism as position control having fast-forward mechanism and hydraulic pressure mechanism as pressurization, was carried out. Then a prototype was produced, and it was done a performance test.

ii) A novel eddy current angle sensor for electro hydraulic rotary valves:We present an eddy current angle sensor for high-pressure electrohydraulic rotary valves. An oblique ring-shaped sensing coil and a symmetric semicylindrical rotor are utilized, making the coil impedance and the output voltage proportional to the angular displacements. Analysis based on an electrical equivalent circuit and the finite-element method is provided, and good agreement is obtained between the simulated and measured results. Extensive experiments have shown that the sensor has a linear working range of about 30 with nonlinearity 0.8% and temperature drift less than 1% over 30 C90 C.

iii)Piston Lock for Power Cylinder:A power cylinder of the type in which the piston may be locked to maintain a fixed position.A pair of guard rods extended in parallel spaced fashion through the bore of the cylinder and the piston includes a pair of spaced apertures passing the guide rods so that the piston may slide within the bore of the cylinder on the guide rods.The piston apertures are internally threaded and the guide rods include an externally threaded portionso that,following movement of the piston within the bore through a rapid advance portion of its stroke under the influence of pressure fluid,the internal threads in the piston apertures are brought into engagement with the externally threaded portions of the guide rods and the guide rods are thereafter rotated so as to threadably advance the piston to its final desired position.

1.4 Objectives of Present Work:In the present paper an inbuilt non contact inductive pick-up type position sensing technique of the piston of a power cylinder made of ferrous alloy material like carbon steel has been proposed.In this technique ,the change of position of the piston is sensed in terms of self inductance change of a coil wound around the outer surface of the power cylinder .The inductance of the coil linearly changes almost linearly with the displacement of the piston from one end of the power cylinder. Proposed work is planned completely in the following steps:Step 1 :- Selection of model power cylinder and its material. Step-2:- Selection of number of turns & diameter of the winding wire. Step 3:- Cs-alloy,different types of alloy steel(carbon steel),cylinder of carbon steel of diameter 4 inch, thickness 3mm,length 300mm is selected. Step 4:- Fabrication of inductance coils of the power cylinder. Step 5:- Design & assembly of the modified transmission & signal conditioning effect. Step 6:- Design of the transmitter circuit. Step 7:- Draw the static characteristic of the proposed position sensors. Step 8:- Draw the static characteristic of the position transducer. Step 9:- Testing & calibration of the proposed position transmitter.

1.5Block Diagram of the whole work:-

2.1 Theory & analysis of proposed Position Sensor:Position sensor is used to measure the displacement.It can measure linear,or angular or rotary displacement.By sensor we can convert one type of energy into another type of energy. A device that measures or detects a real-world condition, such as motion, heat or light and converts the condition into an analog or digital representationIn this project power cylinder is used as a position sensor.

Here we measure different parameters with respect to the variation of the position of the piston inside the power cylinder.

2.2 Theory & analysis of proposed position transducer:Position transducer is used to measure the displacement.

Here we made a transducer by various type of operational amplifiers and resistors.The fuction of the transducer is to convert one type of energy into another type of energy.

2.3 Theory of Instrumentation Amplifier:

Instrumentation Amplifier is a type of differential amplifier that has been outfitted with input buffers,which eliminate the need for input impedence matching and thus make the amplifier particularly suitable for use in measurement and test equipment.Additional characteristics include very low DC offset,low drift,low noise,very high open-loop gain,very high common mode rejection ratio, and very high input impedences.Instrumentaion amplifiers are used where great accuracy ans stability of the circhuit both short and long term are required. Although the instrumentation amplifier is usually shown schematically identical to a standard op-amp,the electronic instrumentation amp is almost always internally composed of 3 op-amps.These are arranged so that there is one op-amp to buffer each input(+.-),and one to produce the desired output with adequate impedance matching for the function. The most commonly used instrumentation amplifier circuit is shown in the figure.

The gain of the circuit is Vout/(V2-V1)=(1+2R1/Rgain)R3/R2 Instrumentation Amplifiers can be built with individual op-amps and precision resistors,but also available in integrated circuit from several manufacturers.An IC instrumentation amplifier typically contains closely matched laser trimmed resistors and therefore offers excellent common-mode rejection.

2.4 Theory of Rectifier and Filter Network:

RC and other filters are very widely used in selecting signals ans rejecting noise.Alow pass filter may be considered as a filter that allow the DC but aatenuat the AC component of a signal that is passing through it.Conversely ,a high pass filter can pass the high frequency signal through it thus it is used it sort high frequency components in a purely AC signal.Capacitor may be considered as high frequency accepter and low frequency rejecter.

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2.5 Theory of zero adjustment circuit:

The output voltage from the sensor is amplified to 1-5 V by the amplifier in the measuring circuit.That is zero of the input voltage is to be adjusted at 1V.This zero may not be adjusted by bridge potentiometer in one of the ratio rms.But this potentiometer should be kept at a value so that the bridge is almost balanced at zero level condition.This is required to get linear bridge output at higher bridge sensitivity condition.Hence accurate zero adjustment should not be done with the bridge potentiometer because of potential balance.So an additional zero adjustment networks have been proposed in our present work.

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2.6 Theory of Span Adjustment Network:

This network is required to adjust the final indication within the whole span of the instrument.It consists of the network as shown in figure below. In this network ,the output voltage Vgo of the gain adjustment network is connected to the common through a potentiometer Ps called span adjustment potentiometer to obtain the voltage signal 5V at maximum level.By adjusting the gain of the gain adjustment network the voltage Vgo can be made higher than 5V so that the potentiometer output voltage Vs=5V is obtained almost central position of the potentiometer wiper.The unity gain amplifier behave as a buffer want to drive the output meter.

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2.7 Theory of Gain Adjustment Network:

This network is needed to adjust the gain of the instrument.This amplifier the output of the zero adjustment networks so that after amplification the signal is sufficient to drive the output indicator throughout its whole range.A simple amplifier circuit having variable feedback resistance in inverting mode is used for this network.

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3.1 Design and fabrication of the proposed Position Sensor:The power cylinder used in the present work has 28 cm length,10 cm diameter.The coil wound on outer surface of the cylinder had 10000 turns of 30SWG super-enameled copper wire.The piston and the covers of the top and bottom are made by mild steel and the cylinder is also made by mild steel.

3.2 Design and fabrication of the proposed Position Transducer:The inductance measuring circuit was designed using low noise OPAMPs like OP07 and watt registers with 1% tolerance.A function generator with output voltage 5 Volts ,100 Hz was used in the experiment.

3.3 Design of instrumentation Amplifier:

To design the instrumentation amplifier we use OP07 as operational amplifier.The major advantageous of this chip charactertistics include i) high common mode rejection ratio(CMRR), ii)high input impedance ,iii) low noice and drift, iv) moderate bandwidth. The circuit components are used as followes: R1=10K

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R=1 K

3.4 Design of Rectfier & Filter network:

A simple diode has been used for Half wave rectification.The circuit of filter is nothing but the parallel combination of R and C shown in the figure described in complete circuit of the project work and the value of the parameters used is given below: R1=10K C=0.1 micro farad.

3.5 Design of Zero Adjustment Circuit:

For zero adjustment a unity gain differential amplifier using OP07 is designed.A pot connected with +15V and -15 V with its two terminals is used for zero adjustment.Here the trim pot may be used for greater stability requirement.The circuit diagram is shown in the figure in chapter 2.And the components are as follows: R1=1k R2=10k Rz=20K

3.6 Design of span and gain adjustment network:

For span adjustment a pot is used.The circuit diagram is shown in chapter 2.And circuit components used are as follows: R1=1K R2=10k

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3.7 Design of Position Transmitter:

For Position Transmitter circuit opamp OP07 ,a transistor,and resistors are used.The circuit diagram is shown in chapter 2 .And circuit components used are as follows: T1=SL150 R1=1k R2=10k

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3.8 Complete Circuit Diagram:

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3.9The whole Set up of the project:

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