Actuator Control Diagnosis Using Reference Properties and Targeted Tests
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing diagnostic methods for process plants fail to provide a clear diagnostic statement regarding the cause of a fault, leading to imprecise identification of error sources and resulting in uneconomical maintenance costs and potential process interruptions.
Innovation Solution
A diagnostic method and data processing system that utilizes a diagnostic database to assign causal correlations between system reference properties and fault causes, combined with a test database to determine appropriate diagnostic tests, enabling unambiguous identification of fault causes through a series of systematic tests.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If existing diagnostic methods are used to identify actuator failures, then fault detection capability is provided, but the precision of root cause identification deteriorates leading to ambiguous diagnosis results
Solution Approach 1:
The diagnostic method segments the fault analysis process into distinct phases: initial symptom detection, necessary condition verification, and definitive cause identification. By dividing the diagnostic workflow into manageable segments with specific verification steps, the system achieves precise root cause identification while maintaining complete diagnostic information through structured progression through each segment.
Solution Approach 2:
The system performs preliminary actions by establishing a comprehensive database of necessary conditions and diagnostic tests before actual fault occurrence. This preparatory work includes pre-defining symptom patterns, test procedures, and decision logic, enabling the system to quickly and accurately identify fault causes when failures occur without losing diagnostic information.
2Measurement precision
If comprehensive diagnostic analysis is performed to identify root causes, then diagnostic accuracy improves, but diagnostic time and system complexity increase
Solution Approach 1:
The system performs preliminary action by pre-establishing a comprehensive database containing all necessary conditions, diagnostic tests, and decision logic before faults occur. This preparation enables rapid fault diagnosis without sacrificing accuracy, as the system can immediately apply pre-defined analysis frameworks rather than building diagnostic logic in real-time.
Solution Approach 2:
The patent replaces complex mechanical diagnostic procedures with automated computer-based analysis. The control system automatically executes diagnostic algorithms, evaluates test results, and identifies root causes without manual intervention, significantly reducing diagnostic time while maintaining high accuracy through systematic computerized analysis.
3Reliability
If multiple diagnostic tests are conducted to ensure accurate fault identification, then diagnosis reliability improves, but maintenance costs and process interruptions increase
Solution Approach 1:
The diagnostic system applies local quality by selecting and executing only the specific diagnostic tests and necessary conditions relevant to the detected fault symptoms. Rather than performing all possible tests uniformly, the system tailors the diagnostic approach to each specific fault condition, ensuring reliable identification while avoiding unnecessary maintenance actions and process interruptions.
Solution Approach 2:
The system implements feedback mechanisms where diagnostic test results are continuously evaluated against necessary conditions, and the analysis progresses only when sufficient evidence is obtained. This feedback-driven approach ensures reliable fault identification by systematically verifying conditions while preventing unnecessary maintenance by stopping the diagnostic process once adequate confidence in the root cause is achieved.
Data Source
Figure 1~2
Figure 3
Figure 4~6
AI summary
The invention relates to a method (100) for diagnosing a control and/or regulating system of a process facility (10) comprising at least one actuator (1) for setting a process fluid, having the steps of a) providing a diagnostic database (1400) which comprises an assignment of multiple state causes (n) to a respective set comprising multiple specified system reference properties (m), wherein each system reference property is assigned a necessary condition (B); b) providing a test database (1500) which comprises an assignment of different diagnostic tests (t) for at least one respective specified system reference property (m); c) detecting (200) at least one actual system property (s, x, z, α) of the control and/or regulating system; d) determining at least one first system reference property (m), the condition (B) of which is satisfied by the at least one actual system property (s, x, z, α) detected in step (c); e) for at least one state cause (n) with a set (N) of specified system reference properties (m), said set comprising the first system reference property (m) determined in step (d), for at least one second system reference property (mx) of said set (N), detecting whether the condition (B) assigned to the second system reference (mx) (i) is certain, preferably satisfied or not satisfied, or (ii) is not certain on the basis of the diagnostic database (1400), in particular using the at least one actual system property/properties (s, x, z, α) detected in step (c); and f) ascertaining at least one diagnostic test (t) on the basis of the test database (1500) corresponding to the at least one second system reference property (mx) with a necessary condition (B) identified as being uncertain in step (d).