Method for selecting and optimizing a sensor, and computer program product

Abstract

The invention relates to a method for selecting and optimizing a sensor, wherein the sensor is designed to detect at least one physical or chemical measurement variable, said method having the steps of: determining the expected process data, master data and standards of the process in which the sensor is used; determining all sensors in question on the basis of the expected process data, master data and standards; determining the measurement properties of at least one sensor from the set of all sensors in question; changing at least one measurement property, measurement properties based on the changed measurement property being changed accordingly; and re-determining all sensors in question on the basis of the expected process data, master data, standards and the changed measurement property. The invention also relates to a computer program product.

Description

[0001] Method for selecting and optimizing a sensor and computer program product

[0002] The invention relates to a method for selecting and optimizing a sensor and a computer program product.

[0003] Before a system, process, or measuring point in process automation technology can be commissioned, a suitable sensor must be selected for the corresponding measurement task. Determining and ultimately selecting the "best" sensor for a specific situation and process is a complex undertaking. The selection is typically based on personnel experience. If a sensor has been selected in a similar situation in the past, the same one is often chosen again.

[0004] In this experience-based process, a sensor is first selected, and a sensor configuration is then checked against process and requirement data. If the process or requirement data is not met, a new sensor configuration is manually created (again by experts based on their experience) and checked again. This is often a trial-and-error process. Even if a seemingly suitable sensor is found, it is not clear whether this is the only configuration or whether there are other, potentially better, configurations.

[0005] It is often unclear what "the best" sensor should be able to do. There are many different "best" sensors, for example, in terms of measurement performance, application area, price, etc.

[0006] A sensor from a valid sensor configuration has certain properties. Changing a parameter in the configuration affects the sensor's properties. For example, the response time of a temperature sensor can vary depending on the thickness of a calculated protective tube. Over time, an expert learns how different parameter changes affect the sensor and what the dependencies are. However, not all dependencies are immediately apparent, and therefore the impact of configuration changes is not always predictable.

[0007] The invention is based on the objective of finding the optimal sensor in process automation technology for an application with specific boundary conditions.

[0008] The task is solved by a procedure comprising the following steps: determining the expected process data, master data, and standards of the process in which the sensor is used; identifying all suitable sensors based on the expected process data, master data, standards, and exclusions; determining the measurement characteristics of at least one sensor from the set of all suitable sensors; changing at least one measurement characteristic, whereby measurement characteristics dependent on the changed measurement characteristic are also changed accordingly; and re-identifying all suitable sensors based on the expected process data, master data, standards, exclusions, and the changed measurement characteristic.

[0009] One design stipulates that the process data includes at least the type of medium, flow rate, pressure, temperature, density, viscosity, flow velocity, fill level, pH value, conductivity, concentration, sum parameters, etc.

[0010] For the process data, ranges can be specified if necessary, for example that the pressure range is between 100 bar and 120 bar.

[0011] One design allows for the specification of fixed values. Fixed values ​​restrict the solution space to the requirements from the outset, and optimizations are only possible within this limited space. This eliminates the risk of selecting an unsuitable sensor or configuration, as all process / requirement parameters have been considered. Another design stipulates that the standards used are certificates and approvals. Examples of such standards include certificates and approvals like EHEDG, 3-A, and PMMI B155 TR3.

[0012] One design stipulates that the master data includes information on communication options, power supply type, the presence of a display, SIL requirements, explosion protection, housing material, price, flange type, connection type and options, material requirements, pipe size, accuracy requirements, maximum or minimum dimensions, etc.

[0013] There is one or more databases that contain the sensor manufacturer's complete portfolio, including all data for each sensor. This database includes sensor type, measurement parameters, measurement accuracy, measurement speed, dimensions, materials, price, explosion protection information, certificates, approvals, output signals, input signals, communication methods, power connections, materials, material properties, housing shapes, housing material, paint finish, color, electrical parameters (voltage, required current, etc.), process connection types, calibration variants, pressure rating, process connection standards, sensor lengths, sensor types, antenna types (for sensors with antennas), protective tube design (e.g., for temperature sensors), cable entry types (how cables are routed into the sensor), etc. In general, it contains all documentable information about a sensor.

[0014] Two types of "exclusions" can be distinguished. Firstly, there are logical-technical exclusions. For example, a sensor cannot have both a metric and an imperial thread simultaneously. Therefore, if the user selects a metric thread, all sensors with imperial threads will not even be suggested. Another logical-technical exclusion is when the user has a limited installation space; sensors requiring more space will not be offered. A further example of an exclusion concerns a sensor with an explosion-proof (Ex) certificate. If an Ex certificate is selected, certain power supplies will no longer be available.

[0015] Another exclusion may be specified by the sensor manufacturer, even if there is no direct technical exclusion. For example, if the user wants to measure a flow rate at a specific pressure, they will only be offered sensors with a diameter of a certain size or larger. While it would theoretically be possible for a sensor with a smaller diameter to meet the requirements, the manufacturer does not offer such a sensor. Alternatively, the manufacturer may link specific process data, master data, standards, or measurement characteristics to a particular product line.

[0016] Once the process data, master data, and standards are defined, the manufacturer's product portfolio, including exclusions, results in a limited selection of potentially suitable sensors. From this pool of possible sensors, the decision-maker must select the best possible one. Even an inexperienced user can choose a sensor that would generally work.

[0017] This selection results in certain measurement characteristics of the sensor.

[0018] One design specifies that the measurement characteristics include pressure drop, noise level, response time, sensor head temperature, wall thickness of a protective tube, arrangement of the sensitive element within the sensor, sensor shape, energy consumption (especially over its entire lifespan), measurement accuracy, measurement frequency, calibration frequency, calibration accuracy, intensity of a radiation source, CO2 emissions during production, CO2 consumption over the lifetime, and possibilities for optimizing the energy consumption for measurement, among other things. For example, optimizing energy consumption could involve using a larger tube diameter, which would result in less pumping power and thus lower energy consumption.

[0019] Therefore, if a specific sensor or sensors are selected, it is clear that the corresponding sensor has certain measurement characteristics, such as a certain response time. The user can then modify one or more of these characteristics, thus optimizing them. For example, a shorter response time might be desired. Due to this modified characteristic, the pool of suitable sensors and their configuration options is further narrowed. In the context of this document, "configuration" or "configuration options" means... 11This includes, for example, the specification of certain parameters, settings, and adjustments of a sensor to detect specific physical or chemical properties and / or the material composition of its environment. This encompasses, for instance, the adaptation of the evaluation electronics and the setting of the signal output, explosion protection specifications, certificates, approvals, output signals, input signals, communication methods, power connections, materials, material properties, housing shapes, housing material, paint finish, color, electrical parameters (voltage, required current, etc.), process connection types, calibration variants, pressure rating, process connection standards, sensor lengths, sensor types, antenna types (for sensors with antennas), protective tube design (e.g., for temperature sensors), cable entry types (how cables are routed into the sensor), calibration options, etc.Only a fully configured sensor can be ordered and manufactured, because only then are all of the sensor's options defined. Depending on the sensor, up to several dozen or even several hundred options can be specified.

[0020] One design stipulates that at least one potential sensor is fully configured.

[0021] Dependencies arise between the measurement characteristics, and potentially also between the measurement characteristics and process data, master data, or standards. For example, if the response time of a temperature sensor needs to be reduced, a sensor with a thinner protective tube wall can be used. However, this can result in the sensor no longer possessing sufficient rigidity for the intended application. In that case, a different material might have to be selected. However, this material might not meet hygiene requirements. Thus, many dependencies arise, the master data for which is stored in the database and whose dependencies are modeled in the computer program.

[0022] It may happen that the desired process data, master data, and standards with the desired measurement properties are not possible. In such cases, a compromise is proposed. Alternatively, it is suggested to modify a single parameter (process data, master data, standards, measurement properties) so that the remaining parameters meet the requirements.

[0023] Instead of checking a single sensor configuration, dependencies between parameters are modeled. Then, calculations are performed based on process and requirement data (process data, master data, and standards) to determine all suitable sensor configurations. With the given requirement data (process data, master data, and standards), all suitable configurations are identified.

[0024] The results obtained can now be used to directly calculate optimizations, i.e., by changing the measurement characteristics. When selecting a configuration, it can be displayed which measurement characteristics could still be optimized.

[0025] This moves away from expert knowledge and assumptions and towards precise calculations and genuine verifiability as to why exactly this sensor configuration was used. It is also possible to demonstrate that it is the optimal sensor configuration for the requirements.

[0026] One design envisages identifying the sensor that represents the best possible compromise between expected process data, master data, standards, exclusions, and the changed measurement characteristics.

[0027] One design provides that alternative measurement properties are determined if the desired modified measurement properties are not feasible.

[0028] One design provides that suitable replacement parts are identified for at least one potentially suitable sensor.

[0029] The problem is further solved by a computer program product comprising program instructions which, when executed on a computer system, cause the computer system to perform a method as described above. Based on the claimed method, the best sensor is determined for the given requirements, including process data, master data and standards, exclusions, and, most importantly, optimized measurement characteristics.

[0030] A recommendation can be made as to which is the best sensor, e.g. the sensor with the lowest pressure loss, with high accuracy in all application areas for the media used.

[0031] Another recommendation might offer even better accuracy, but at a higher price.

[0032] Ultimately, the user can decide which sensor is optimal for them under the given conditions.

[0033] This allows for the calculation of the optimal sensor instead of a "best-guess" approach. Standards are incorporated (e.g., hygiene certificates, corrosive media, etc.) directly during the design phase. This method systematizes and automates error-prone manual steps. The decision remains traceable, even during later calibration or replacement.

Claims

Patent claims 1. Method for selecting and optimizing a sensor, wherein the sensor is designed to detect at least one physical or chemical quantity, comprising the steps - Determining the expected process data, master data and standards of the process in which the sensor is used; - Identifying all potential sensors based on expected process data, master data, standards and exclusions; - Determining the measurement characteristics of at least one sensor from the set of all eligible sensors; - Changing at least one measurement property, whereby measurement properties dependent on the changed measurement property are also changed accordingly; and - Re-identifying all potential sensors based on the expected process data, master data, standards, exclusions and the changed measurement characteristics.

2. Method according to claim 1, wherein the process data includes at least the type of medium, flow rate, pressure, temperature, density, viscosity, flow velocity, fill level, pH value, conductivity, concentration, sum parameters, etc.

3. Method according to claim 1 or 2, wherein the standards are certificates and approvals.

4. Method according to one of the preceding claims, wherein the master data comprises information on communication options, power supply type, the presence of a display, SIL requirement, explosion protection, housing material, price, flange type, connection type and options, material requirements, pipe size, accuracy requirements, maximum or minimum dimensions, etc.

5. Method according to one of the preceding claims, wherein the measurement characteristics are pressure drop, volume, response time, sensor head temperature, wall thickness of a protective tube, arrangement of the sensitive element in the sensor, sensor shape, energy consumption, in particular during its entire lifetime, measurement accuracy, measurement frequency, calibration frequency, calibration accuracy, strength of a radiation source, CO2 emissions during production, CO2 demand during lifetime, possibilities for optimizing the energy demand for measurement, etc.

6. Method according to one of the preceding claims, wherein the sensor is determined which represents the best possible compromise between expected process data, master data, standards, exclusions and the changed measuring characteristic.

7. A method according to any of the preceding claims, wherein alternative measurement properties are determined if the desired modified measurement properties are not feasible.

8. Method according to one of the preceding claims, wherein suitable spare parts are determined for at least one suitable sensor.

9. Method according to one of the preceding claims, wherein at least one suitable sensor is fully configured.

10. Computer program product comprising program instructions which, when executed on a computer device, cause the computer device to execute a method according to any of the preceding claims.

11. Methods for optimizing or replacing an existing sensor in a process automation system, for example with regard to new requirements, comprising the following steps: - Identifying the sensor to be optimized or replaced; and - Applying the method according to one of claims 1 to 9 to the sensor to be optimized or replaced.