Actuator Position Detection via Digital Image Analysis
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Solution Overview
Problem
Existing methods for detecting the position of adjustable control elements in process engineering systems require significant technical effort, intervention, and may pose safety risks, especially in environments with explosive substances, and lack efficient non-contact solutions.
Innovation Solution
A method using digital image data from an image recording device, evaluated by computing devices with image evaluation software, including artificial intelligence, to determine the position of actuating elements without additional components or contact, utilizing markings or spatial orientation for position identification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If magnetic field sensors and additional components are installed on the control device to detect position, then position detection accuracy is improved, but device complexity and technical effort increase
Solution Approach 1:
The patent uses optical copying by capturing images of the control element with a camera. Instead of installing magnetic sensors on the device, the system creates a visual copy (image) of the control element and analyzes its position through image processing, thereby avoiding additional hardware installation while maintaining detection capability
Solution Approach 2:
The patent replaces the mechanical/electromagnetic detection system (magnetic field sensors) with an optical system (camera-based image capture and processing). This substitution eliminates the need for physical contact or electromagnetic fields near the control device, reducing technical complexity while achieving position detection through digital image analysis
2Reliability
If contact-based detection methods are used to obtain position information, then measurement reliability is improved, but safety risks increase in explosive environments
Solution Approach 1:
The patent introduces light as an intermediary between the detection system and the control element. The camera captures reflected light from the control element's markings without physical contact or electromagnetic interference, providing a safe measurement method for explosive environments while maintaining reliable position detection through optical mediation
Solution Approach 2:
The patent replaces contact-based mechanical detection with non-contact optical detection. By using a camera to capture images and analyze markings on the control element, the system eliminates physical contact that could generate sparks or heat, thereby ensuring safety in explosive atmospheres while maintaining measurement reliability through digital image processing
3Difficulty of detecting and measuring
If additional detection components are installed on the control device, then position detection capability is improved, but ease of operation deteriorates due to installation requirements
Solution Approach 1:
The patent uses visual copying through image capture to detect control element position without installing any components on the device. The camera creates a digital replica of the control element's appearance and markings, allowing position determination through software analysis alone, thereby maintaining detection capability while eliminating installation requirements
Solution Approach 2:
The patent substitutes the physical installation of detection components with a software-based image processing system. By replacing hardware installation with digital image capture and analysis, the system maintains full position detection capability while dramatically improving ease of operation, as no physical modification to the control device is needed
Data Source
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AI summary
The invention relates, inter alia, to a method for detecting the position of an adjustable actuator (11) of a technical control device (10) of a process plant (100) by generating a position indicator (SA) specifying the position of the actuator (11). According to the invention, digital image data (BD), comprising an image of the actuator (11) or at least a part of the actuator (11), are generated by an image acquisition device (20), and the digital image data (BD) are evaluated by a computing device (40) programmed with image evaluation software (BAS) to generate the position indicator (SA).