Sensor multi-point calibration system and method

Abstract

The invention discloses a sensor multi-point calibration system and method, and relates to the technical field of sensor calibration, the sensor multi-point calibration system comprises a sensor, a control module, an execution module and an interaction module; the sensor is used for measuring a target parameter, obtaining a real-time value CH of the parameter and sending the real-time value CH to the control module; the control module is used for analyzing whether the sensor has a signal source drift phenomenon; if the signal source of the sensor drifts, the control module calibrates the real-time value CH to obtain an adjustment value VA, and sends a calibration instruction to the execution module according to the adjustment value VA; the execution module is used for adjusting the target parameter to a set value according to the calibration instruction; according to the invention, the sensor can be calibrated and the error can be corrected in the operation process of the equipment without dismounting the sensor or removing the equipment from the production line and sending the equipment to a calibration laboratory, so that the problem that the production efficiency is influenced because the production process needs to be interrupted in the existing calibration mode is effectively solved.

Description

Technical Field

[0001] The present invention relates to the technical field of sensor calibration, and more particularly to a sensor multi-point calibration system and method. Background Art

[0002] A sensor is a precision detection device that can accurately sense and respond to changes in physical, chemical or biological quantities in the external environment. By converting these changes into electrical signals or other forms of signals, sensors provide the necessary input data for various measurement, monitoring and control systems. They are widely used in many fields such as industrial automation, environmental monitoring, medical diagnosis, smart homes, transportation, etc., and are an indispensable part of modern technology. Sensors are usually designed for specific measurement targets and have high sensitivity, accuracy, stability and response speed to ensure the reliability of measurement results.

[0003] As sensors age, signal source drift is inevitable. This drift may cause the accuracy of measurement data to decrease, which in turn affects decision making and process control. Temperature changes in the field environment, component aging, mechanical stress, electromagnetic interference, and power supply fluctuations can all cause signal source drift. Temperature changes can affect the properties of sensor materials, causing measurement parameter offsets; component aging can cause sensor performance to degrade over time, resulting in reduced accuracy; mechanical stress can cause slight changes in sensor structure, affecting measurement results; electromagnetic interference can introduce additional noise signals, affecting signal stability; and power supply fluctuations can cause unstable power supply to the measurement equipment, affecting measurement accuracy.

[0004] If the signal source drift of the sensor is not properly managed and corrected, the accuracy of the measurement results will be reduced, which may lead to a decline in product quality in the production process, instability in equipment control, errors in safety monitoring, and unreliable data in scientific research, which may ultimately cause economic losses, equipment damage, environmental impacts or safety accidents. Therefore, regular calibration and maintenance of sensors are the key to ensuring their long-term stable operation and providing reliable data.

[0005] The existing methods for dealing with sensor signal source drift are mostly calibration or sensor replacement. Most of the existing calibrations require disassembling the sensor or removing the device from the production line and sending it to the calibration laboratory. This process temporarily interrupts the production process and requires extra time to complete these tasks, resulting in production delays. In some cases, if the calibration cycle is not properly scheduled or there is a backlog of calibration services, the waiting time of the equipment in the calibration laboratory may be extended, thus affecting production efficiency. Another method of replacing the sensor will increase costs. Summary of the invention

[0006] In view of the deficiencies in the prior art, an object of the present invention is to provide a sensor multi-point calibration system and method.

[0007] To achieve the above-mentioned object, the present invention provides the following technical solutions: a sensor multi-point calibration system, comprising a sensor, a control module, an execution module and an interaction module; The sensor is used to measure the target parameter, obtain the real-time value CH of the parameter, and send the real-time value CH to the control module; The control module is used to analyze whether the sensor has a signal source drift phenomenon; If the signal source of the sensor has no drift phenomenon, the control module sends a conventional instruction to the execution module; If the signal source of the sensor drifts, the control module calibrates the real-time value CH to obtain the adjustment value VA, and sends a calibration instruction to the execution module according to the adjustment value VA; The execution module is used to adjust the target parameter to a set value according to the calibration instruction issued by the control module; The interaction module is connected to the sensor, the control module and the execution module respectively, and the interaction module is used to monitor and manage the operation of the system; During the operation of the equipment, you first need to set the set value of the target parameter, and then measure the target parameter through the sensor. For example, set the temperature of the target parameter, and then measure the temperature of the target parameter through the temperature sensor; If the sensor's signal source has no drift phenomenon, the target parameters are adjusted through the execution module, for example, the target is heated by a heating element, so that the real-time value CH measured by the sensor is equal to the set value; If the signal source of the sensor drifts, the real-time value CH measured by the sensor will have an error. The real-time value CH is calibrated by the control module to obtain the adjustment value VA, and the calibration instruction is sent to the execution module according to the adjustment value VA. The execution module can adjust the target parameter to the set value, thereby correcting the error caused by the drift phenomenon. Moreover, the present application does not require the disassembly of the sensor or the removal of the equipment from the production line and sending it to a calibration laboratory. The sensor can be calibrated and the error corrected during the operation of the equipment, effectively solving the problem that the existing calibration method requires interrupting the production process and affecting production efficiency.

[0008] A further technical solution of the present application is: the sensor includes a temperature sensor, a flow sensor and a pressure sensor.

[0009] A further technical solution of the present application: the control module includes an analysis unit, a calibration unit and an output unit; The analysis unit is used to determine whether the sensor has a signal source drift phenomenon; If the signal source of the sensor has no drift phenomenon, the output unit sends a conventional instruction to the execution module; If the signal source of the sensor drifts, the calibration unit selects five calibration points V_HH, V_H, V_M, V_L and V_LL in sequence within the range according to the range of the sensor, and the five calibration points correspond to five calibration values ​​D_HH, D_H, D_M, D_L and D_LL respectively; The calibration unit calibrates the real-time value CH in sections. If the real-time value CH is between V_HH and V_H, the adjustment value VA is calculated by the formula: [(CH-V_H) / (V_HH-V_H)]×[(V_HH+D_HH)-(V_H+D_H)]+(V_H+D_H); If the real-time value CH is between V_H and V_M, the adjustment value VA is calculated by the formula: [(CH-V_M) / (V_H-V_M)]×[(V_H+D_H)-(V_M+D_M)]+(V_M+D_M); If the real-time value CH is between V_M and V_L, the adjustment value VA is calculated by the formula: [(CH-V_L) / (V_M-V_L)]×[(V_M+D_M)-(V_L+D_L)]+(V_L+D_L); If the real-time value CH is between V_L and V_LL, the adjustment value VA is calculated by the formula: [(CH-V_LL) / (V_L-V_LL)]×[(V_L+D_L)-(V_LL+D_LL)]+(V_LL+D_LL); The output unit sends a calibration instruction to the execution module according to the adjustment value VA.

[0010] A further technical solution of the present application is as follows: the execution module includes a water pump, a valve, a heating element and a cooling element.

[0011] A further technical solution of the present application is as follows: the sensor multi-point calibration system also includes a feedback adjustment module, and the feedback adjustment module is used to perform cyclic verification on the adjustment result of the execution module.

[0012] A further technical solution of the present application is: the interaction module is used to set relevant parameters, including set values, calibration points and calibration values; The interactive module is also used to display system operation data in real time and trigger an alarm mechanism when various data exceed a set range.

[0013] A further technical solution of the present application: the interaction module is also used to store system operation data and send the system operation data to the host computer.

[0014] The present application also provides a sensor multi-point calibration method, which is applied to the sensor multi-point calibration system described above. The sensor multi-point calibration method comprises the following steps: S1: Set the set value, calibration point and related parameters of the calibration value through the interactive module; S2: Measure the target parameter through the sensor, obtain the real-time value CH of the parameter, and send the real-time value CH to the control module; S3: Determine whether the sensor has signal source drift through the control module; S4: If the signal source of the sensor has no drift phenomenon, the output unit sends a regular instruction to the execution module; If the signal source of the sensor drifts, the calibration unit calibrates the real-time value CH in sections and calculates the adjustment value VA through the formula. The output unit sends a calibration instruction to the execution module according to the adjustment value VA. S5: The execution module adjusts the target parameter to the set value according to the calibration instruction; S6: The interactive module displays the system operation data in real time and triggers the alarm mechanism when various data exceed the set range.

[0015] Compared with the prior art, the present invention has the following beneficial effects: 1. If the signal source of the sensor drifts, the real-time value CH measured by the sensor will have an error. The real-time value CH is calibrated by the control module to obtain the adjustment value VA, and the calibration instruction is sent to the execution module according to the adjustment value VA. The execution module can adjust the target parameter to the set value, thereby correcting the error caused by the drift phenomenon; and the present application does not need to disassemble the sensor or remove the equipment from the production line and send it to the calibration laboratory. The sensor can be calibrated and the error can be corrected during the operation of the equipment, which effectively solves the problem that the existing calibration method needs to interrupt the production process and affect the production efficiency; 2. The present invention uses multi-point calibration technology to ensure the accuracy of the sensor between different calibration points. This multi-point calibration method can more comprehensively evaluate the performance of the sensor, improve the overall measurement accuracy, and cover the entire measurement range of the sensor, ensuring that accurate measurement results can be obtained at each measurement point. It can ensure the stability and reliability of the sensor during long-term use and reduce measurement errors caused by signal drift.

[0016] The above description is only an overview of the technical solution of the present invention. In order to more clearly understand the technical means of the present invention and implement it according to the contents of the specification, the following is a detailed description of the preferred embodiments of the present invention in conjunction with the accompanying drawings. The specific implementation of the present invention is given in detail by the following embodiments and their accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The drawings described herein are used to provide a further understanding of the present invention and constitute a part of this application. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the drawings: Figure 1 The figure is a flow chart of a multi-point calibration method for a sensor in an embodiment of the present invention. DETAILED DESCRIPTION

[0018] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0019] In the description of the embodiments of the present invention, it should be noted that if the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc. appear, the directions or positional relationships indicated are based on the directions or positional relationships shown in the drawings, or are the directions or positional relationships in which the invented product is usually placed when in use. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific direction, be constructed and operated in a specific direction, and therefore cannot be understood as limiting the present invention. In addition, the terms "first", "second", "third", etc. are only used to distinguish the description, and cannot be understood as indicating or implying relative importance.

[0020] In the present invention, unless otherwise clearly specified and limited, the terms "installed", "connected", "connected", "fixed" and the like should be understood in a broad sense, for example, it can be connected, detachably connected, or integrated; it can be mechanically connected or electrically connected; it can be directly connected or indirectly connected through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0021] Embodiment 1 In one embodiment of the present application, a sensor multi-point calibration system includes a sensor, a control module, an execution module, and an interaction module; The sensor is used to measure the target parameter, obtain the real-time value CH of the parameter, and send the real-time value CH to the control module; the control module is responsible for receiving various sensor signals, and performing data processing and decision-making according to the preset program logic, and finally outputting control instructions; The control module is used to analyze whether the sensor has a signal source drift phenomenon; If the signal source of the sensor has no drift phenomenon, the control module sends a conventional instruction to the execution module; the execution module does not take any action after receiving the conventional instruction; If the signal source of the sensor drifts, the control module calibrates the real-time value CH to obtain the adjustment value VA, and sends a calibration instruction to the execution module according to the adjustment value VA; The execution module is used to adjust the target parameter to a set value according to the calibration instruction issued by the control module; The interactive module is connected to the sensor, control module and execution module respectively, and is used to monitor and manage the operation of the system, and provides a user-friendly operation interface for setting calibration parameters, displaying real-time data, alarm prompts and fault diagnosis functions; During the operation of the equipment, you first need to set the set value of the target parameter, and then measure the target parameter through the sensor. For example, set the temperature of the target parameter, and then measure the temperature of the target parameter through the temperature sensor; If the sensor's signal source has no drift phenomenon, the target parameters are adjusted through the execution module, for example, the target is heated by a heating element, so that the real-time value CH measured by the sensor is equal to the set value; If the signal source of the sensor drifts, the real-time value CH measured by the sensor will have an error. The real-time value CH is calibrated by the control module to obtain the adjustment value VA, and the calibration instruction is sent to the execution module according to the adjustment value VA. The execution module can adjust the target parameter to the set value, thereby correcting the error caused by the drift phenomenon. Moreover, the present application does not require the disassembly of the sensor or the removal of the equipment from the production line and sending it to a calibration laboratory. The sensor can be calibrated and the error corrected during the operation of the equipment, effectively solving the problem that the existing calibration method requires interrupting the production process and affecting production efficiency.

[0022] As a preferred embodiment of the present application, the sensor includes a temperature sensor, a flow sensor and a pressure sensor.

[0023] As a preferred embodiment of the present application, the control module includes an analysis unit, a calibration unit and an output unit; The analysis unit is used to determine whether the sensor has a signal source drift phenomenon; If the signal source of the sensor has no drift phenomenon, the output unit sends a conventional instruction to the execution module; If the signal source of the sensor drifts, the calibration unit selects five calibration points V_HH, V_H, V_M, V_L and V_LL in sequence within the range according to the range of the sensor, and the five calibration points correspond to five calibration values ​​D_HH, D_H, D_M, D_L and D_LL respectively; The calibration unit calibrates the real-time value CH in sections. If the real-time value CH is between V_HH and V_H, the adjustment value VA is calculated by the formula: [(CH-V_H) / (V_HH-V_H)]×[(V_HH+D_HH)-(V_H+D_H)]+(V_H+D_H); If the real-time value CH is between V_H and V_M, the adjustment value VA is calculated by the formula: [(CH-V_M) / (V_H-V_M)]×[(V_H+D_H)-(V_M+D_M)]+(V_M+D_M); If the real-time value CH is between V_M and V_L, the adjustment value VA is calculated by the formula: [(CH-V_L) / (V_M-V_L)]×[(V_M+D_M)-(V_L+D_L)]+(V_L+D_L); If the real-time value CH is between V_L and V_LL, the adjustment value VA is calculated by the formula: [(CH-V_LL) / (V_L-V_LL)]×[(V_L+D_L)-(V_LL+D_LL)]+(V_LL+D_LL); The output unit sends a calibration instruction to the execution module according to the adjustment value VA; This application uses multi-point calibration technology to ensure the accuracy of the sensor between different calibration points. This multi-point calibration method can more comprehensively evaluate the performance of the sensor and improve the overall measurement accuracy. It also covers the entire measurement range of the sensor to ensure accurate measurement results at each measurement point. It can ensure the stability and reliability of the sensor during long-term use and reduce measurement errors caused by signal drift.

[0024] As a preferred embodiment of the present application, the execution module includes a water pump, a valve, a heating element and a cooling element, and makes corresponding adjustments according to the calibration instructions of the control module.

[0025] As a preferred embodiment of the present application, the sensor multi-point calibration system further includes a feedback adjustment module, and the feedback adjustment module is used to perform cyclic verification on the adjustment result of the execution module, so as to achieve precise control.

[0026] As a preferred embodiment of the present application, the interaction module is used to set relevant parameters, including set values, calibration points and calibration values; The interactive module is also used to display system operation data in real time and trigger an alarm mechanism when various data exceed a set range.

[0027] As a preferred embodiment of the present application, the interaction module is also used to store system operation data and send the system operation data to the host computer.

[0028] The multi-point calibration function of this application can ensure that the sensor can maintain high-precision measurement in multiple positions or conditions. Combined with high-precision calibration equipment, the sensor is calibrated in all directions and at multiple angles, thereby improving the measurement accuracy of the sensor. In some application scenarios, such as robot calibration systems, non-contact calibration methods (such as laser ranging) can avoid errors and damage that may be caused by physical contact, while also improving the flexibility and convenience of calibration. This system has a flexible interface and configurability, and can adapt to many different types of sensors and measuring equipment. Therefore, it can not only be used for calibration of specific types of sensors, but also can be expanded to a wider range of applications to meet the calibration needs in different scenarios. By designing an intuitive and easy-to-use operating interface and an automated calibration process, the complexity and difficulty of the calibration operation are reduced. Users only need to follow simple steps to complete the multi-point calibration of the sensor, which improves work efficiency and user experience. In the long run, this system can significantly reduce the calibration cost. Because it can realize batch calibration of multiple sensors, it reduces repetitive labor and labor costs; at the same time, by improving calibration accuracy and reliability, it reduces the additional costs caused by measurement errors.

[0029] Embodiment 2 Reference Figure 1 In another embodiment of the present application, a multi-point sensor calibration method is also proposed, comprising the following steps: S1: Set the set value, calibration point and related parameters of the calibration value through the interactive module; S2: Measure the target parameter through the sensor, obtain the real-time value CH of the parameter, and send the real-time value CH to the control module; S3: Determine whether the sensor has signal source drift through the control module; S4: If the signal source of the sensor has no drift phenomenon, the output unit sends a regular instruction to the execution module; If the signal source of the sensor drifts, the calibration unit calibrates the real-time value CH in sections and calculates the adjustment value VA through the formula. The output unit sends a calibration instruction to the execution module according to the adjustment value VA. S5: The execution module adjusts the target parameter to the set value according to the calibration instruction; S6: The interactive module displays the system operation data in real time and triggers the alarm mechanism when various data exceed the set range.

[0030] Embodiment 3 In another embodiment of the present application, a calibration method for a sensor that has been removed from a device is also proposed, comprising the following steps: S1: System Preparation S1.1: Connect the sensor to be calibrated to the corresponding interface of the calibration bench; S1.2: Check whether all pipes and valves are tightly connected and leak-free; S1.3: Start the computer, open the software, and make necessary settings; S2: Set calibration parameters S2.1: Set the calibration scheme in the software, including calibration points, calibration values, calibration sequence, etc.; S2.2: Select appropriate calibration standards and specifications based on sensor type and application scenario; S3: Start calibration S3.1: The calibration system starts to work and applies gases or liquids with different parameters to the sensor in sequence according to the preset calibration scheme; S3.2: At each calibration point, the system records the output signal of the sensor and compares it with the standard value; S4: Data processing and calibration parameter calculation S4.1: The calibration software processes the collected data, including filtering, denoising and other steps, to improve the accuracy and reliability of the data; S4.2: Calculate sensor calibration parameters such as offset, gain, etc. based on the processed data.

[0031] The above is only a preferred embodiment of the present invention, and the protection scope of the present invention is not limited to the above embodiments. All technical solutions under the concept of the present invention belong to the protection scope of the present invention. It should be pointed out that for ordinary technicians in this technical field, some improvements and modifications without departing from the principle of the present invention should also be regarded as the protection scope of the present invention.

[0032] In addition, it should be understood that although the present specification is described according to implementation modes, not every implementation mode contains only one independent technical solution. This description of the specification is only for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment may also be appropriately combined to form other implementation modes that can be understood by those skilled in the art.

Claims

1. A sensor multi-point calibration system, characterized in that: It includes sensors, control modules, execution modules and interaction modules; The sensor is used to measure the target parameter, obtain the real-time value CH of the parameter, and send the real-time value CH to the control module; The control module is used to analyze whether the sensor has a signal source drift phenomenon; If the signal source of the sensor has no drift phenomenon, the control module sends a conventional instruction to the execution module; If the signal source of the sensor drifts, the control module calibrates the real-time value CH to obtain the adjustment value VA, and sends a calibration instruction to the execution module according to the adjustment value VA; The execution module is used to adjust the target parameter to a set value according to the calibration instruction issued by the control module; The interaction module is connected to the sensor, the control module and the execution module respectively, and the interaction module is used to monitor and manage the operation of the system.

2. A sensor multi-point calibration system according to claim 1, characterized in that: The sensors include a temperature sensor, a flow sensor and a pressure sensor.

3. A sensor multi-point calibration system according to claim 1, characterized in that: The control module includes an analysis unit, a calibration unit and an output unit; The analysis unit is used to determine whether the sensor has a signal source drift phenomenon; If the signal source of the sensor has no drift phenomenon, the output unit sends a conventional instruction to the execution module; If the signal source of the sensor drifts, the calibration unit selects five calibration points V_HH, V_H, V_M, V_L and V_LL in sequence within the range according to the range of the sensor, and the five calibration points correspond to five calibration values ​​D_HH, D_H, D_M, D_L and D_LL respectively; The calibration unit calibrates the real-time value CH in sections. If the real-time value CH is between V_HH and V_H, the adjustment value VA is calculated by the formula: [(CH-V_H) / (V_HH-V_H)]×[(V_HH+D_HH)-(V_H+D_H)]+(V_H+D_H); If the real-time value CH is between V_H and V_M, the adjustment value VA is calculated by the formula: [(CH-V_M) / (V_H-V_M)]×[(V_H+D_H)-(V_M+D_M)]+(V_M+D_M); If the real-time value CH is between V_M and V_L, the adjustment value VA is calculated by the formula: [(CH-V_L) / (V_M-V_L)]×[(V_M+D_M)-(V_L+D_L)]+(V_L+D_L); If the real-time value CH is between V_L and V_LL, the adjustment value VA is calculated by the formula: [(CH-V_LL) / (V_L-V_LL)]×[(V_L+D_L)-(V_LL+D_LL)]+(V_LL+D_LL); The output unit sends a calibration instruction to the execution module according to the adjustment value VA.

4. A sensor multi-point calibration system according to claim 3, characterized in that: The execution module includes a water pump, a valve, a heating element and a cooling element.

5. A sensor multi-point calibration system according to claim 4, characterized in that: The sensor multi-point calibration system further includes a feedback adjustment module, which is used to perform cyclic verification on the adjustment result of the execution module.

6. A sensor multi-point calibration system according to claim 5, characterized in that: The interactive module is used to set relevant parameters, including set values, calibration points and calibration values; The interactive module is also used to display system operation data in real time and trigger an alarm mechanism when various data exceed a set range.

7. A sensor multi-point calibration system according to claim 6, characterized in that: The interaction module is also used to store system operation data and send the system operation data to the host computer.

8. A sensor multi-point calibration method, applied to a sensor multi-point calibration system according to any one of claims 1 to 7, characterized in that: The sensor multi-point calibration method comprises the following steps: S1: Set the set value, calibration point and related parameters of the calibration value through the interactive module; S2: Measure the target parameter through the sensor, obtain the real-time value CH of the parameter, and send the real-time value CH to the control module; S3: Determine whether the sensor has signal source drift through the control module; S4: If the signal source of the sensor has no drift phenomenon, the output unit sends a regular instruction to the execution module; If the signal source of the sensor drifts, the calibration unit calibrates the real-time value CH in sections and calculates the adjustment value VA through the formula. The output unit sends a calibration instruction to the execution module according to the adjustment value VA. S5: The execution module adjusts the target parameter to the set value according to the calibration instruction; S6: The interactive module displays the system operation data in real time and triggers the alarm mechanism when various data exceed the set range.

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