This project is part of my Control & Instrumentation Engineering Portfolio and demonstrates a Sensor Calibration System using TwinCAT 3.1.
It simulates a real-world use case where analog sensor inputs (e.g. a PT100 temperature probe) require calibration to ensure accurate and reliable engineering unit outputs.
This TwinCAT 3.1 project includes:
- ✅ Scaling Function Block for a PT100 sensor connected via a Beckhoff EL3202 RTD input card.
- ✅ Calibration Function Block that supports multi-point calibration using linear interpolation.
- ✅ An interactive SCADA-style visualization with trend data and calibration options.
- ✅ Data entry table for modifying reference points live during runtime.
- ✅ Option to apply or reset calibration via checkboxes.
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Multi-Point Calibration:
- Uses two arrays:
SensorPoints– The actual measured input values.ReferencePoints– The true/desired values (from a calibrator).
- Applies linear interpolation between these points.
- Uses two arrays:
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Live Readings:
- Shows both non-calibrated and calibrated output values for comparison.
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Visualization:
- A heatmap-style calibration graph.
- Text boxes and a clean layout to demonstrate calibration effects in real-time.
Here is a screengrab of the system in action:
You can explore the project files and code in the repo:
🔗 Sensor-Calibration on GitHub
- Add logging functionality for calibration sessions.
- Support for other sensor types like 4–20 mA pressure transducers.
- Improved interpolation algorithms (e.g. polynomial or piecewise linear).
This project was developed as part of a professional engineering portfolio in the field of Electrical, Control, and Instrumentation Engineering.