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 for devices in automation processes, leading to unexpected downtime and significant economic losses due to sudden malfunctions, with a lack of effective methods 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 defective device data, calculates an integrity index value by comparing real-time operational data, and outputs this value to managers for proactive management and maintenance.
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 device monitors its own integrity by utilizing its existing control output signals. The integrity detection system uses signals already generated by the device's normal operation, eliminating the need for separate sensors or additional monitoring hardware. This self-service approach improves reliability while minimizing system complexity.
Solution Approach 2:
The patent introduces an integrity detection system that acts as an intermediary between the device's control signals and the monitoring requirements. This intermediary component processes existing control output signals to extract integrity information, providing reliable monitoring without directly adding complex sensing infrastructure to the device itself.
2Measurement precision
If comprehensive integrity detection is performed using multiple detecting conditions, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The integrity detection is divided into multiple detecting conditions (first, second, third detecting conditions) that segment the monitoring process into distinct evaluation stages. Each condition checks specific aspects of device integrity using control output signals, allowing comprehensive assessment while maintaining clear, modular detection logic that manages system complexity.
Solution Approach 2:
The detection system dynamically applies different detecting conditions based on device operation states. The system can adaptively select which integrity checks to perform by evaluating control output signal characteristics, enabling precise measurement without requiring all detection mechanisms to operate simultaneously, thus managing complexity.
3Loss of time
If real-time integrity monitoring is implemented, then loss of time due to unexpected downtime is reduced, but use of energy for monitoring increases
Solution Approach 1:
The integrity monitoring operates continuously by utilizing control output signals that are already being generated during device operation. Since the monitoring uses signals inherent to normal device operation rather than requiring separate active sensing, it achieves continuous surveillance with minimal additional energy consumption, reducing downtime losses without significant energy penalty.
Solution Approach 2:
The monitoring system creates a virtual copy of device operation data by analyzing control output signals instead of requiring physical sensors. This copying approach extracts integrity information from existing control commands, enabling real-time monitoring with minimal additional energy expenditure since no separate sensing hardware needs to be actively powered.
Data Source
AI summary
Disclosed is an integrity index detecting method for a device by means of a control output signal including an integrity information collecting step S10 of measuring and collecting a time interval between a control output signal and a subsequent control output signal; a defect information collecting step S20 of measuring and collecting a time interval between a control output signal and a subsequent control output signal; a setting step S30 of setting an integrity reference value and a defect reference value for the time interval between the control output signals; a detecting step S40 of measuring and collecting the time interval value between a control output signal and a subsequent control output signal; and an outputting step S50 of outputting the integrity index value detected in the detecting step S40 to provide the integrity index value to the manager.