Lecture 4.

Data conversion devices

Data Conversion Devices are very important components of a Machine Control Unit
(MCU). MCUs are controlled by various computers or microcontrollers which are
accepting signals only in Digital Form i.e. in the form of 0s and 1s, while the signals
received from signal conditioning module or sensors are generally in analogue form
(continuous). Therefore a system is essentially required to convert analog signals into
digital form and vis-à-vis. Analog to Digital Converter is abbreviated as ADC. Figure
2.8.1 shows a typical control system with data conversion devices.

Based on the signals received from sensors, MCU generates actuating signals in the
Digital form. Most of the actuators e.g. DC servo motors only accept analogue
signals. Therefore the digital signals must be converted into Analog form so that the
required actuator can be operated accordingly. For this purpose Digital to Analog
Converters are used, which are abbreviated as DACs. In subsequent sections we will
be discussing about various types of ADC and DAC devices, their principle of
working and circuitry.

Figure 2.8.1 A control system with ADC and DAC devices

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Basic components used in ADCs and DACs

1. Comparators
In general ADCs and DACs comprise of Comparators. Comparator is a combination
of diodes and Operational Amplifiers. A comparator is a device which compares the
voltage input or current input at its two terminals and gives output in form of digital
signal i.e. in form of 0s and 1s indicating which voltage is higher. If V+ and V- be
input voltages at two terminals of comparator then output of comparator will be as
V+ > V-  Output 1
V+ < V-  Output 0

2. Encoders

Though the output obtained from comparators are in the form of 0s and 1s, but can’t
be called as binary output. A sequence of 0s and 1s will be converted into binary form
by using a circuit called Encoder. A simple encoder converts 2n input lines into ‘n’
output lines. These ‘n’ output lines follow binary algebra.

3. Analog to Digital Converter (ADC)

As discussed in previous section ADCs are used to convert analog signals into Digital
Signals. There are various techniques of converting Analog Signals into Digital
signals which are enlisted as follows. However we will be discussing only Direct
Conversion ADC, detail study of other techniques is out of the scope of the present
course.

1. Direct Conversion ADC or Flash ADC

2. Successive Approximation ADC
3. A ramp-compare ADC
4. Wilkinson ADC
5. Integrating ADC
6. Delta-encoded ADC or counter-ramp
7. Pipeline ADC (also called subranging quantizer)
8. Sigma-delta ADC (also known as a delta-sigma ADC)
9. Time-interleaved ADC

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3.1 Direct Conversion ADC or Flash ADC

Figure 2.8.2 Circuit of Flash ADC

Figure 2.8.2 shows the circuit of Direct conversion or Flash ADC. To convert a digital
signal of N-bits, Flash ADC requires 2N-1 comparators and 2N resistors. The circuit
provides the reference voltage to all the comparators. Each comparator gives an
output of 1 when its analog voltage is higher than reference voltage or otherwise the
output is 0. In the above circuit, reference voltages to comparators are provided by
means of resistor ladder logic.

The circuit described in figure 2.8.2 acts as 3 Bit ADC device. Let us assume this
ADC works between the range of 0-10 Volts. The circuit requires 7 comparators and
8 resisters. Now the voltages across each resistor are divided in such a way that a
ladder of 1 volt is built with the help of 1K-Ohm resistances. Therefore the reference
voltages across all the comparators are 1-7 volts.

Now let us assume that an input voltage signal of 2.5 V is to be converted into its
related digital form. As 2.5V is greater than 1V and 2V, first two comparators will
give output as 1, 1. But 2.5V is less than 3,4,5,6,7 V values therefore all other
comparators will give 0s. Thus we will have output from comparators as 0000011
(from top). This will be fed to the encoder logic circuit. This circuit will first change
the output in single high line format and then converts it into 3 output lines format by
using binary algebra. Then this digital output from ADC may be used for
manipulation or actuation by the microcontrollers or computers.

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4. Digital to Analog Converters
As discussed in previous section DACs are used to convert digital signals into Analog
Signals. There are various techniques of converting Digital Signals into Analog
signals which are as follows however we will be discussing only few important
techniques in detail:

1. Pulse-width modulator
2. Oversampling DACs or interpolating DACs
3. The binary-weighted DAC
4. Switched resistor DAC
5. Switched current source DAC
6. Switched capacitor DAC
7. The R-2R ladder
8. The Successive-Approximation or Cyclic DAC,
9. The thermometer-coded DAC

4.1 Binary Weighted DAC

Figure 2.8.3 Circuit of binary weighted DAC

Figure 2.8.4 An op-amp used in DAC

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 As name indicates, in binary weighted DAC, output voltage can be calculated by
expression which works on binary weights. Its circuit can be realized in Figure
2.8.3. From the figure it can be noted that most significant bit of digital input is
connected to minimum resistance and vice versa. Digital bits can be connected to
resistance through a switch which connects resistance-end to the ground. The
digital input is zero when former bit is connected to reference voltage and if it is
1. This can be understood from Figure 2.8.4. DAC output voltage can be
calculated from property of operational amplifiers. If V1 be input voltage at MSB
(most significant bit), V2 be input voltage at next bit and so on then for four bit
DAC we can write,
𝑉1 𝑉2 𝑉3 𝑉4 𝑉𝑜𝑢𝑡
+ + + = (2.8.1)
𝑅 2𝑅 4𝑅 8𝑅 𝑅

Note: Here V1,V2 V3,V4 will be Vref if digital input is 1 or otherwise it will be
zero.

Hence output voltage can be found as:

𝑉𝑂𝑈𝑇 𝛼 (23 ∗ 𝑉1 + 22 ∗ 𝑉2 + 21 ∗ 𝑉3 + 20 ∗ 𝑉4) (2.8.2)

However Binary weighted DAC doesn’t work for multiple or higher bit systems as the
value of resistance doubles in each case.

Thus simple and low bit digital signals from a transducer can be converted into a
related continuous value of voltages (analogue) by using binary weighted DAC. These
will further be used for manipulation or actuation.

4.2 R-2R Ladder based DAC

Figure 2.8.5 R-2R Ladder based DAC

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 In R-2R ladder logic, shortcoming of Binary Logic has been removed by making
the value of maximum resistance double however the rest of the circuit remains
same. Figure 2.8.5 shows the circuit of R-2R Ladder based DAC. If we apply
voltage division rule in above case, then we can calculate that output voltage as,
𝑉𝑟𝑒𝑓 ∗ 𝑅𝑓
𝑉𝑜𝑢𝑡 = 𝑅
∗ 𝑉𝐴𝐿 (2.8.3)

Where VAL can be calculated from the digital signal input as,
𝐷0 𝐷1 𝐷2 𝐷3
𝑉𝐴𝐿 = + + + (2.8.4)
24 23 22 23

In this way output voltage is obtained by converting the digital signals received
from microprocessor/ microcontroller. These voltages will further be used to
actuate the desired actuator viz. DC/AC motors.

In this module we have studied the principle of operation of various sensors which
are commonly used in mechatronics and manufacturing automation. Also the
signal conditioning operations and the devices which are used to generate the
proper signals for desired automation application have been studied. In the next
module we will study the construction and working of microprocessor and the
devices which are being used in controlling the various operations of automation
using the microprocessors.

Quiz

1. Differentiate between Binary weighted DAC and R-2R ladder based DAC.
2. Explain the importance of data conversion devices in mechatronics with
suitable example.

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