Calibration Signal Support for Stable Field Device Adjustment
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Solution Overview
Problem
Calibration accuracy and efficiency in industrial plants are compromised due to the skill dependence of maintenance workers and the time required for output stabilization in field devices, leading to variable results.
Innovation Solution
A calibration work support device and method that includes a pressure gauge, pressure calibrator, and pressure generator, connected via cables and air tubes, which adjusts and records input and output values to ensure accurate calibration by determining proper ranges and stability conditions, thereby reducing skill dependence and optimizing calibration time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the output value is measured before stabilization time elapses, then work efficiency is improved, but calibration accuracy deteriorates
Solution Approach 1:
The system continuously monitors the output value and compares it against the target value, automatically adjusting the input signal and notifying the operator when stabilization is achieved. This feedback mechanism eliminates the need for operators to manually judge stabilization timing, ensuring both accuracy and efficiency.
Solution Approach 2:
The calibration system performs self-adjustment by automatically modifying the input signal based on real-time output monitoring. The system serves itself by detecting when calibration is complete and notifying operators, reducing dependency on operator skill and experience.
2Measurement precision
If the output value is measured after waiting for a long time, then calibration accuracy is improved, but work efficiency deteriorates
Solution Approach 1:
The system provides real-time feedback on calibration progress and automatically detects when the output value has stabilized within the acceptable range. This eliminates unnecessary waiting time while ensuring accuracy is maintained, as the system stops calibration precisely when the target is achieved.
Solution Approach 2:
The system replaces the mechanical/manual process of waiting and judging stabilization with an automated electronic monitoring and control system. The computer automatically tracks the output value and determines when calibration is complete, substituting human judgment with precise electronic measurement.
3Device complexity
If manual adjustment of simulation signal is performed, then device complexity is reduced, but measurement precision deteriorates due to skill dependence
Solution Approach 1:
The calibration system performs self-adjustment by automatically modifying the input simulation signal based on real-time output monitoring. The system adjusts the signal magnitude and timing without operator intervention, ensuring consistent precision regardless of operator skill level while maintaining relatively simple hardware.
Data Source
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AI summary
A calibration work support device includes a calibration target setter that sets a target value of a simulation signal input to a device in calibration of the device, a simulation signal acquirer that acquires an input value based on the simulation signal, a proper range determiner that determines whether the input value is within a proper range for the target value, a proper range notifier that notifies a user whether the input value is within the proper range, an output value acquirer that acquires an output value output from the device in accordance with the simulation signal, a condition determiner that determines whether at least one of the input value and the output value satisfies a predetermined condition, and a recorder that records the input value and the output value if at least one of the input value and the output value satisfies the predetermined condition.