Control Output Signal Timing for Real-Time Device Integrity Detection
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Solution Overview
Problem
Existing methods fail to provide real-time integrity monitoring of devices in automation processes, leading to unexpected downtime and significant losses due to sudden malfunctions, as they lack effective means to detect device integrity before failures occur.
Innovation Solution
An integrity index detecting method using control output signals, which establishes a reference table based on normal and defect data, applies gradient values to time intervals, and outputs an integrity index value to managers for proactive management and inspection planning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If real-time integrity monitoring is implemented using control output signals, then device reliability and safety are improved, but system complexity and implementation cost increase
Solution Approach 1:
The monitoring system utilizes existing control output signals that are already generated by the controller for device operation, rather than requiring separate dedicated sensing systems. By analyzing timing information from these multi-purpose control signals, the system achieves integrity monitoring without adding dedicated hardware complexity
Solution Approach 2:
The controller itself generates the data needed for monitoring through its normal operation. The control output signals that drive the device also contain the timing information needed for integrity assessment, allowing the system to monitor itself without external intervention or additional sensors
2Measurement precision
If continuous monitoring of control output signals is performed, then detection precision is improved, but energy consumption increases
Solution Approach 1:
The system measures time intervals between control output signals and compares them against reference values to generate integrity index information. This feedback mechanism uses simple temporal comparisons rather than continuous complex analysis, maintaining detection precision while minimizing energy consumption
Solution Approach 2:
The monitoring operates by periodically measuring time intervals between control output signals at their natural occurrence frequency. Rather than using continuous high-power sampling, the system leverages the periodic nature of control signals to achieve precise monitoring with minimal energy input
3Measurement precision
If integrity index reference table is established with multiple detecting conditions, then detection precision is improved, but device complexity increases
Solution Approach 1:
The integrity assessment is divided into discrete detecting conditions (first detecting condition, second detecting condition, etc.), each with specific time interval thresholds. This segmentation allows complex integrity assessment to be broken down into manageable comparison operations, improving precision without overwhelming system complexity
Solution Approach 2:
The system uses time interval values as the key parameter for integrity assessment. By changing the parameter being monitored from physical device states to temporal characteristics of control signals, the system achieves precise integrity detection through simple time measurements and comparisons
Data Source
AI summary
The present invention relates to an integrity index detecting method for a device by means of a control output signal which, after establishing an integrity index reference table based on an integrity reference value set based on information collected from a normal device and a defect reference value set based on information collected from a device before a malfunction occurs, outputs an integrity index value indicating an integrity of the device in real time by applying a gradient value with respect to a time interval value between control output signals collected from the device in real time to the integrity index reference table to provide the integrity index value to a manager.