How to Create an Automatic Sensor Test on the AT-2040
The AT-2040 Gen 2 lets you create automatic sensor test setups directly on the instrument. Define the sensor type, sensitivity, reference point, frequency sweep, and amplitude levels, then run a repeatable calibration sequence without building the test by hand each time.
Automatic test workflow
- Create or select a sensor setup
- Enter manufacturer and part number
- Select sensor type and units
- Define reference frequency and amplitude
- Add frequency/amplitude test points
- Run the test and export PDF/CSV results
What an automatic test does
An automatic sensor test runs a stored set of vibration points and records the measured sensor response at each point. Instead of manually changing the frequency and amplitude for every step, the AT-2040 automatically moves through the predefined sequence.
Automatic tests are useful for full calibrations, repeatable frequency response checks, production verification, and calibration lab workflows where the same sensor model must be tested the same way every time.
Automatic test setup includes
Use automatic tests for repeatable calibration work
Manual mode is best for quick checks and troubleshooting. Automatic Sensor Test mode is best when the same procedure needs to be run consistently across multiple sensors or across multiple calibration events.
Full calibration
Run a multi-point calibration sweep and record sensitivity across the sensor’s working range.
Production testing
Use the same stored setup for each sensor model so every unit is tested the same way.
Incoming inspection
Verify sensors before they are placed into service or added to inventory.
Repeatable records
Save test results and export PDF or CSV files for customer documentation and internal quality systems.
Plan the sensor test first
Before entering a new sensor setup, review the sensor datasheet, prior certificate, customer requirements, and AT-2040 operating limits. A good automatic test starts with a realistic frequency and amplitude plan.
Start with the reference point
Define the main reference frequency and amplitude first. For many accelerometers, this is commonly 100 Hz at 1 g, unless the customer or sensor certificate specifies something different.
Choose the sweep points
Select frequencies that cover the sensor’s operating range and your required calibration points. Do not add unnecessary points that do not support the purpose of the test.
Check amplitude limits
Make sure each frequency and amplitude combination is within the AT-2040 shaker capability and does not exceed the sensor’s input limit.
Use safe frequency and amplitude combinations
The AT-2040 validates frequency and amplitude entries to help protect the shaker and sensor. Lower frequencies are often displacement-limited, while higher frequencies can become force or payload limited.
When planning a custom automatic test, use lower amplitudes when needed and avoid test points that exceed the shaker limit for the sensor mass and fixture mass.
Practical planning guide
- Use reduced amplitudes at low frequency.
- Use normal reference amplitudes in the mid-frequency range where practical.
- Reduce amplitude at high frequency when needed.
- When in doubt, use a lower vibration level.
- Do not exceed the sensor’s rated input level.
Create a custom automatic sensor test
Use the Test Setup screen when the sensor is not already in the AT-2040 database or when you need a custom calibration procedure.
Open Settings
From the main menu, select Settings.
Open Test Setup
Select Test Setup to create or edit a sensor configuration.
Enter manufacturer
Enter the sensor manufacturer name. This field is required.
Enter part number
Enter the sensor model or part number. This field is required.
Select sensor type
Choose the correct input type, such as IEPE, Charge, Voltage, Proximity, Velocity, or 4–20 mA.
Save the setup
After entering the setup details and test points, save the configuration to the internal database.
Recommended fields to enter
The exact fields depend on the sensor type, but most automatic tests require sensor identity, sensitivity, units, reference point, and test point data.
| Field | What to enter | Why it matters |
|---|---|---|
| Manufacturer | Sensor manufacturer name | Used to organize the sensor in the database. |
| Part number | Sensor model or part number | Used to identify the exact sensor setup. |
| Sensor type | IEPE, Charge, Voltage, Prox, Velocity, 4–20 mA, or other supported type | Selects the correct input path and measurement behavior. |
| Units | g, m/s², IPS, mm/s, mils, mm, µm, or transmitter units | Controls how the test points and results are displayed. |
| Sensitivity | Rated sensor sensitivity from the datasheet or prior certificate | Used to calculate deviation and compare response. |
| Reference frequency | Main calibration reference frequency | Used as the baseline for sensitivity and deviation. |
| Reference amplitude | Main calibration vibration level | Defines the primary test condition. |
| Frequency/amplitude table | Each automatic test point | Defines the sweep the AT-2040 will run automatically. |
Choose the correct sensor type
The sensor type determines how the AT-2040 routes the input signal, displays units, and calculates sensitivity.
IEPE accelerometer
Use for powered IEPE accelerometers, typically measured in mV/g with bias voltage readback.
Charge accelerometer
Use for charge output sensors, typically measured in pC/g through the charge input path.
Voltage output sensor
Use for voltage accelerometers or DC/AC voltage-output sensors, commonly measured in mV/g or V/g.
Velocity sensor
Use velocity units such as IPS or mm/s and sensitivity such as mV/IPS or mV/mm/s.
Proximity probe
Use displacement units such as mils, mm, or µm and monitor gap voltage where applicable.
4–20 mA transmitter
Use for current-loop vibration transmitters and verify output against the configured full-scale range.
Example automatic accelerometer test points
These example points are only a starting point. Your actual test setup should follow your lab procedure, customer requirements, sensor datasheet, and the AT-2040 amplitude limits.
| Step | Frequency | Amplitude | Purpose |
|---|---|---|---|
| 1 | 10 Hz | Reduced amplitude | Low-frequency response check |
| 2 | 50 Hz | Customer-defined | Low/mid-frequency response |
| 3 | 100 Hz | Reference amplitude | Main sensitivity reference point |
| 4 | 200 Hz | Customer-defined | Mid-frequency response |
| 5 | 500 Hz | Customer-defined | Frequency response check |
| 6 | 1,000 Hz | Customer-defined | Upper frequency response check |
Run the automatic sensor test
Once the setup is saved, the sensor can be selected from the Sensor Test screen and run automatically.
Mount the sensor
Mount the sensor to the AT-2040 using the correct stud, adapter, or fixture.
Connect the sensor
Connect the sensor to the correct input channel or adapter cable for that sensor type.
Open Sensor Test
From the main menu, select Sensor Test.
Select manufacturer
Select the manufacturer from the database list.
Select sensor model
Select the saved sensor setup or model number.
Start the test
Press Start and let the AT-2040 run through the programmed sequence.
Use graph view or table view
Automatic test data is shown in graph view by default. The graph shows deviation relative to the reference sensitivity, while table view shows each test point and fills in the results as the test progresses.
During the test, the screen can show status, reference measurement, current step, serial number, graph/table toggle, and Start/Stop control. For IEPE sensors, bias voltage may also be displayed. For proximity probes, gap voltage may be displayed.
Status meanings
- Ready: test has not started.
- Testing: automatic sweep is running.
- Stopped: test was stopped before completion.
- Complete: all programmed test points are finished.
- Done: table/step sequence is complete.
Save and export automatic test results
At the end of the automatic test, the AT-2040 saves the data to onboard memory. The results can be recalled later and exported for customer records or internal quality documentation.
Calibration certificate
Export a PDF report for documentation, review, or customer delivery.
Measured data
Export CSV data for spreadsheets, databases, or quality-system records.
File transfer
Use the Reports screen and USB export workflow to move completed test data off the instrument.
Automatic test does not force a pass/fail decision
The AT-2040 provides measured sensitivity, deviation, phase data where applicable, status, and calibration records. It does not force a universal pass/fail result because each laboratory may have its own tolerance, uncertainty budget, and decision rule.
If a statement of conformity is required, apply your lab’s ISO 17025 decision rule or the specific decision rule requested by the customer.
Common automatic test setup problems
Sensor does not appear in the list
Confirm the custom sensor setup was saved, the manufacturer and part number were entered, and the correct manufacturer is selected from the Sensor Test screen.
Amplitude entry is rejected
The selected amplitude may exceed the limit at that frequency or in that unit. Reduce amplitude, change the frequency, or review the shaker limit chart before saving the point.
Results look wrong after changing units
Stay in one unit system while creating the setup. If you change units after entering points, review the point values and re-enter them if needed.
Tips for better automatic tests
Use clear naming
Use manufacturer and part number names that are easy for technicians to recognize.
Match the datasheet
Use sensitivity, units, and frequency range that match the sensor documentation.
Do not overload the shaker
Check sensor mass, fixture mass, frequency, and amplitude before creating high-level points.
Review the report
Verify serial number, test points, and results before sending the certificate to the customer.
Agate Technology can help you create the right AT-2040 sensor test workflow.
Whether you are building a calibration procedure for IEPE sensors, charge accelerometers, velocity sensors, proximity probes, voltage sensors, or 4–20 mA transmitters, the AT-2040 can support repeatable automatic testing and PDF/CSV result export.
