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In this thesis, an integrated flow sensor for an optogalvanic spectrometer is studied. Optogalvanic spectroscopy can be used for carbon isotope analysis when, e.g., searching life in space. At the heart of the spectrometer is a microplasma source, in which the analysis is performed. This master thesis examines the possibilities to integrate a flow sensor inside the microplasma source, to be able to improve the isotopic analysis. The report covers design, manufacturing and evaluation of both the device and the experimental setup. The device was manufactured by milling and lamination of printed circuit board, in which both the plasma source and sensors were incorporated. The final results shows that the sensor had a linear and reliable flow response in a range between 1-15 sccm, and, quite surprisingly, that is simultaneously could measure the pressure in a range between 1-6 Torr. In other words, not only one but two sensors were integrated in the spectrometer at once. The work has been done at the Ångström Space Technology Center - a research group within the Department of Engineering Science at Uppsala University.

Este trabalho apresenta o desenvolvimento de um sensor térmico de vazão integrado a um microcanal. Todo o ciclo de desenvolvimento é abordado: conceito, modelagem e simulação, fabricação e caracterização. O sensor é composto por um filamento de níquel fabricado sobre uma lâmina de vidro que é soldada a um bloco de polidimetilsiloxano (PDMS) contendo microcanais. A aferição da vazão no interior do microcanal é feita indiretamente através da medida da troca de calor entre o filamento e o fluido. As simulações por elementos finitos mostraram que o sensor apresenta três faixas de operação, sendo que em duas delas (fluxos menores do que 20 L/min ou maiores do que 130 L/min) a resposta elétrica do sensor varia linearmente com a vazão. Diversos sensores foram fabricados seguindo o processo de fabricação proposto e alguns dispositivos foram caracterizados eletricamente, tendo sido levantadas as curvas da tensão elétrica sobre o filamento em função da vazão no microcanal. Os resultados experimentais mostraram que os sensores fabricados são capazes de medir vazões da ordem de dezenas de microlitros por minuto na faixa de operação de menor sensibilidade. Métodos de fabricação alternativos foram propostos com o intuito de aumentar a sensibilidade do sensor, produzindo filamentos auto-sustentados no interior dos microcanais. Foi proposto um modelo para simulação comportamental dos sensores otimizados por elementos concentrados e os resultados preliminares tanto de simulação quanto de fabricação desses sensores foram apresentados. / This project presents the development of a thermal flow sensor integrated into a microchannel. The whole design cycle is discussed: concept, modeling and simulation, fabrication and characterization. The sensor consists of a nickel filament fabricated on a glass substrate which is bonded to a polydimethylsiloxane (PDMS) block containing the microchannels. The flow inside the microchannel is indirectly measured through the heat exchange between the filament and the fluid. Finite methods analysis revealed that the sensor has three operating ranges and in two of them (flows below 20 ìL/min or higher than 130 ìL/min) the electric response of the sensor varies linearly with respect to the flow. Several flow sensors were fabricated according to the fabrication method presented in this project and some of them were characterized electrically. The response of the voltage on the filament as a function of the flow inside the microchannel was obtained. The experimental results demonstrated that the flow sensors could measure flow rates as small as tens of microliters per minute even when working on the less sensitive operating range. Alternative fabrication methods were proposed in order to improve the sensor sensitivity, leaving the filaments self-sustained inside the microchannels. A lumped element model was introduced in order to simulate the behavior of the optimized flow sensors. Some preliminary results of these simulations and of the fabrication processes were presented.

This research focuses on developing sensors for properties of aerodynamic interest (i.e., flow and pressure) based on low-cost polymeric materials and simple fabrication processes. Such sensors can be fabricated in large arrays, covering the surface of airfoils typically used in unmanned vehicles, allowing for the detection of flow separation. This in turn potentially enables, through the use of closed-loop control, an expansion of the flight envelope of these vehicles. A key advance is compensation for the typically inferior performance of these low cost materials through both careful design as well as new readout methods that reduce drift, namely a readout methodology based on aeroelastic flutter. An all-polymer micromachined piezoresistive flow sensor is fabricated, based on a flexible polyimide substrate and an elastomeric piezoresistive composite material. The flow sensor comprises a cantilever that is extended into the embedding flow; flow-induced stress on the cantilever is sensed through the piezoresistive composite material. Increasing the sensitivity of the sensor is achieved by either utilizing a long single-cantilever beam or using a dual-cantilever beam supporting a flap extending into the flow. In the latter case, the sensor demonstrates increased sensitivity with a reduced cantilever length. The increase in sensitivity helps to reduce sensor drift, which in turn is further reduced by a new measurement method, the vibration amplitude measurement method. In this drift reduction measurement method, the flow-induced vibration amplitude of the sensor structure (i.e., the amplitude of the aeroelastic flutter induced by the flow), instead of the absolute value of cantilever deflection, is measured in order to find the flow rate. Measurement of this relative resistance change instead of the absolute resistance in the piezoresistor rejects common-mode drift and greatly reduces overall drift. Experimental results verify the expected drift reduction. Sensor drift is also reduced when the elastomeric piezoresistive material is replaced by a Pt thin film piezoresistor. Development of pressure sensors based on polymers proceeds by encapsulating a reference cavity within a multilayer polymer structure and forming capacitor plates on the polymeric membranes encapsulating the cavity. Measuring the capacitance change induced by changes in the embedding pressure (which cause changes in the positions of the bounding polymeric membranes) enables calculation of the pressure. The use of polymeric membranes requires understanding the leakage rate of gas into the reference cavity, which is a source of pressure drift. Developing a polymer-based pressure sensor that solves the problem of sensor drift as a result of gas permeation entails the fabrication of a silicon pressure reference cavity embedded in the polymer substrate, which results in a more hermetic and lower drift sensor while preserving the flexibility of the embedding polymer. Both wired and wireless versions of pressure and flow sensors of these types were developed and characterized. Further, the sensors were characterized on airfoils and their performance in a wind tunnel was determined.

Este trabalho apresenta o desenvolvimento de um sensor térmico de vazão integrado a um microcanal. Todo o ciclo de desenvolvimento é abordado: conceito, modelagem e simulação, fabricação e caracterização. O sensor é composto por um filamento de níquel fabricado sobre uma lâmina de vidro que é soldada a um bloco de polidimetilsiloxano (PDMS) contendo microcanais. A aferição da vazão no interior do microcanal é feita indiretamente através da medida da troca de calor entre o filamento e o fluido. As simulações por elementos finitos mostraram que o sensor apresenta três faixas de operação, sendo que em duas delas (fluxos menores do que 20 L/min ou maiores do que 130 L/min) a resposta elétrica do sensor varia linearmente com a vazão. Diversos sensores foram fabricados seguindo o processo de fabricação proposto e alguns dispositivos foram caracterizados eletricamente, tendo sido levantadas as curvas da tensão elétrica sobre o filamento em função da vazão no microcanal. Os resultados experimentais mostraram que os sensores fabricados são capazes de medir vazões da ordem de dezenas de microlitros por minuto na faixa de operação de menor sensibilidade. Métodos de fabricação alternativos foram propostos com o intuito de aumentar a sensibilidade do sensor, produzindo filamentos auto-sustentados no interior dos microcanais. Foi proposto um modelo para simulação comportamental dos sensores otimizados por elementos concentrados e os resultados preliminares tanto de simulação quanto de fabricação desses sensores foram apresentados. / This project presents the development of a thermal flow sensor integrated into a microchannel. The whole design cycle is discussed: concept, modeling and simulation, fabrication and characterization. The sensor consists of a nickel filament fabricated on a glass substrate which is bonded to a polydimethylsiloxane (PDMS) block containing the microchannels. The flow inside the microchannel is indirectly measured through the heat exchange between the filament and the fluid. Finite methods analysis revealed that the sensor has three operating ranges and in two of them (flows below 20 ìL/min or higher than 130 ìL/min) the electric response of the sensor varies linearly with respect to the flow. Several flow sensors were fabricated according to the fabrication method presented in this project and some of them were characterized electrically. The response of the voltage on the filament as a function of the flow inside the microchannel was obtained. The experimental results demonstrated that the flow sensors could measure flow rates as small as tens of microliters per minute even when working on the less sensitive operating range. Alternative fabrication methods were proposed in order to improve the sensor sensitivity, leaving the filaments self-sustained inside the microchannels. A lumped element model was introduced in order to simulate the behavior of the optimized flow sensors. Some preliminary results of these simulations and of the fabrication processes were presented.

abstract: This thesis investigated two different thermal flow sensors for intravascular shear stress analysis. They were based on heat transfer principle, which heat convection from the resistively heated element to the flowing fluid was measured as a function of the changes in voltage. For both sensors, the resistively heated elements were made of Ti/Pt strips with the thickness 0.12 µm and 0.02 µm. The resistance of the sensing element was measured at approximately 1.6-1.7 kohms;. A linear relation between the resistance and temperature was established over the temperature ranging from 22 degree Celsius to 80 degree Celsius and the temperature coefficient of resistance (TCR) was at approximately 0.12 %/degree Celsius. The first thermal flow sensor was one-dimensional (1-D) flexible shear stress sensor. The structure was sensing element sandwiched by a biocompatible polymer "poly-para-xylylene", also known as Parylene, which provided both insulation of electrodes and flexibility of the sensors. A constant-temperature (CT) circuit was designed as the read out circuit based on 0.6 µm CMOS (Complementary metal-oxide-semiconductor) process. The 1-D shear stress sensor suffered from a large measurement error. Because when the sensor was inserted into blood vessels, it was impossible to mount the sensor to the wall as calibrated in micro fluidic channels. According to the previous simulation work, the shear stress was varying and the sensor itself changed the shear stress distribution. We proposed a three-dimensional (3-D) thermal flow sensor, with three-axis of sensing elements integrated in one sensor. It was in the similar shape as a hexagonal prism with diagonal of 1000 µm. On the top of the sensor, there were five bond pads for external wires over 500 µm thick silicon substrate. In each nonadjacent side surface, there was a bended parylene branch with one sensing element. Based on the unique 3-D structure, the sensor was able to obtain data along three axes. With computational fluid dynamics (CFD) model, it is possible to locate the sensor in the blood vessels and give us a better understanding of shear stress distribution in the presence of time-varying component of blood flow and realize more accurate assessment of intravascular convective heat transfer. / Dissertation/Thesis / M.S. Electrical Engineering 2011

abstract: This dissertation presents my work on development of deformable electronics using microelectromechanical systems (MEMS) based fabrication technologies. In recent years, deformable electronics are coming to revolutionize the functionality of microelectronics seamlessly with their application environment, ranging from various consumer electronics to bio-medical applications. Many researchers have studied this area, and a wide variety of devices have been fabricated. One traditional way is to directly fabricate electronic devices on flexible substrate through low-temperature processes. These devices suffered from constrained functionality due to the temperature limit. Another transfer printing approach has been developed recently. The general idea is to fabricate functional devices on hard and planar substrates using standard processes then transferred by elastomeric stamps and printed on desired flexible and stretchable substrates. The main disadvantages are that the transfer printing step may limit the yield. The third method is "flexible skins" which silicon substrates are thinned down and structured into islands and sandwiched by two layers of polymer. The main advantage of this method is post CMOS compatible. Based on this technology, we successfully fabricated a 3-D flexible thermal sensor for intravascular flow monitoring. The final product of the 3-D sensor has three independent sensing elements equally distributed around the wall of catheter (1.2 mm in diameter) with 120° spacing. This structure introduces three independent information channels, and cross-comparisons among all readings were utilized to eliminate experimental error and provide better measurement results. The novel fabrication and assembly technology can also be applied to other catheter based biomedical devices. A step forward inspired by the ancient art of folding, origami, which creating three-dimensional (3-D) structures from two-dimensional (2-D) sheets through a high degree of folding along the creases. Based on this idea, we developed a novel method to enable better deformability. One example is origami-enabled silicon solar cells. The solar panel can reach up to 644% areal compactness while maintain reasonable good performance (less than 30% output power density drop) upon 40 times cyclic folding/unfolding. This approach can be readily applied to other functional devices, ranging from sensors, displays, antenna, to energy storage devices. / Dissertation/Thesis / Doctoral Dissertation Electrical Engineering 2014

<div>To continue the shift from batch operations to continuous operations for a wider range of products, advances in real-time process management (RTPM) are necessary. The key requirements for effective RTPM are to have reliable real-time data of the critical process parameters (CPP) and critical quality attributes (CQA) of the materials being processed, and to have robust control strategies for the rejection of disturbances and setpoint tracking.</div><div><br></div><div>Real-time measurements are necessary for capturing process dynamics and implement feedback control approaches. The mass flow rate is an additional important CPP in continuous manufacturing compared to batch processing. The mass flow rate can be used to control the composition and content uniformity of drug products as well as an indicator of whether the process is in a state of control. This is the rationale for investigating real-time measurement of mass flow of particulate streams. Process analytical technology (PAT) tools are required to measure particulate flows of downstream unit operations, while loss-in-weight (LIW) feeders only provide initial upstream flow rates. A novel capacitance-based sensor, the ECVT sensor, has been investigated in this study and demonstrates the ability to effectively measure powder mass flow rates in the downstream equipment.</div><div><br></div><div>Robust control strategies can be utilized to respond to variations and disturbances in input material properties and process parameters, so CQAs of materials/products can be maintained and the amount of off-spec production can be reduced. The hierarchical control system (Level 0 equipment built-in control, Level 1 PAT based PID control and Level 2 optimization-based model predictive control) was applied in the pilot plant at Purdue University and it was demonstrated that the use of active process control allows more robust continuous process operation under different risk scenarios compared to a more rigid open-loop process operation within predefined design space. With the aid of mass flow sensing, the control framework becomes more robust in mitigating the effects of upstream disturbances on product qualities. For example, excursions in the mass flow from an upstream unit operation, which could force a shutdown of the tablet press and/or produce off-spec tablets, can be prevented by proper control and monitoring of the powder flow rate entering the tablet press hopper.</div><div><br></div><div>In this study, the impact of mass flow sensing on the control performance of a direct compaction line is investigated by using flowsheet modeling implemented in MATLAB/Simulink to examine the control performance under different risk scenarios and effects of data sampling (sampling time, measurement precision). Followed by the simulation work, pilot plant studies are reported in which the mass flow sensor is integrated into the tableting line at the exit of the feeding-and-blending system and system performance data is collected to verify the effects of mass flow sensing on the performance of the overall plant-wide supervisory control.</div>

Indiana University-Purdue University Indianapolis (IUPUI) / In this work we have designed and simulated a thermal bi-directional integrated circuit mass flow sensor. The approach used here was an extension to the gas flow model given by Mayer and Lechner. The design features high precision response received from analog integrated circuits. A computational fluid dynamic (CFD) model was designed for simulations with air and water Using COMSOL Multiphysics. Established mathematical models for the heat flow equations including CFD parameters were used within COMSOL simulation(COMSOL Multiphysics, Sweden). Heat pulses of 55 °C for a period of nearly 120 seconds and 50% duty cycles were applied as thermal sources to the flowstream. The boundary conditions of the heat equations at the solid (heating element) fluid interface were set up in the software for the thermal response. The hardware design included one heating element and two sensing elements to detect the bi-directional mass flow. Platinum sensors were used due to their linear characteristics within 0 ºC to 100 ºC range, and their high temperature coefficient(0.00385 Ω/Ω/ºC). Polyimide thinfilm heater was used as the heating element due to its high throughput and good thermal efficiency. Two bridge circuits were used to sense the temperature distribution in the vicinity of the sensing elements. Three high precision instrumentation low power amplifiers with offset voltage ~2.5μV (50μV max) were used for bridge signal amplification and the difference circuit. The difference circuit was used to indicate the flow direction. A LM555 timer chip was utilized to provide the heat pulse period. Simulation and experimental measurements for heat pulses with different amplitude (temperature) were in good agreement. Also, the sensitivity of the flow sensor was observed to remain unaffected with the change in the duty cycle of the heat operation mode.

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