Calibration Signal Graphing for Accurate Field Device Adjustment
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Solution Overview
Problem
Manual calibration of field devices in industrial plants leads to variability in calibration results due to human error and inefficiencies, affecting accuracy and efficiency.
Innovation Solution
A calibration work support device and method that automates the calibration process by connecting a pressure gauge, pressure calibrator, and pressure generator, using a software configuration with modules for setting calibration points, acquiring input and output values, generating graphs, and determining calibration accuracy, thereby reducing human intervention and improving precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual calibration is performed by a worker adjusting simulation signal values while visually confirming calibrator readings, then the calibration process can be completed with simple equipment, but calibration accuracy decreases due to variation in manual operation and working efficiency is degraded due to time-consuming adjustment work
Solution Approach 1:
The patent replaces the manual mechanical adjustment system with an automated computer-controlled system. The computer automatically adjusts the simulation signal values and controls the pressure generator, eliminating manual operation variability and significantly improving both calibration accuracy and working efficiency.
Solution Approach 2:
The calibration system performs self-adjustment through automated feedback control. The computer monitors the calibrator readings and automatically adjusts the simulation signal to achieve target values, enabling the system to calibrate itself without human intervention and improving both precision and efficiency.
2Measurement precision
If manual adjustment of simulation signal values is performed by a worker, then equipment complexity remains low, but calibration accuracy decreases due to human error and variation in manual work
Solution Approach 1:
The patent replaces manual mechanical adjustment with computerized automatic control. The computer system manages the entire calibration process including signal generation, adjustment, and measurement, which improves accuracy while the software-based control keeps the overall system complexity manageable.
Solution Approach 2:
The computer acts as an intermediary between the simulation signal source and the calibration target device. It mediates the adjustment process by automatically calculating and applying the necessary signal modifications, eliminating human error while maintaining system simplicity through software intelligence.
Data Source
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AI summary
A calibration work support device includes a calibration target setter configured to set a target value of a simulation signal that is input to a device in calibration of the device and an input order of the target value in the calibration, a simulation signal acquirer configured to acquire an input value based on the simulation signal input to the device, a graph generator configured to generate a graph indicating a transition of the target value set by the calibration target setter and the input value acquired by the simulation signal acquirer, and a data output unit configured to output the graph generated by the graph generator.