Integrated Dry Block Calibrator for Stable Multi-Protocol Calibration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing temperature dry blocks face instability due to unreliable mains voltage and require multiple devices for different calibration protocols, making them unsafe and inconvenient for industrial use.
Innovation Solution
An integrated multifunctional process calibrator with a dry block that supports heating, cooling, and various fieldbus protocols, allowing for a single device to calibrate multiple sensor types and protocols, with built-in safety features and battery power for portability and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a dry block uses mains voltage powered heaters for heating, then heating capability is achieved, but temperature stability deteriorates due to unstable mains voltage
Solution Approach 1:
The patent replaces mains voltage powered heaters with battery powered heating elements. This substitution eliminates the dependency on unstable mains voltage, providing stable and controlled power delivery to the heating elements, thereby maintaining temperature stability while achieving reliable heating capability.
Solution Approach 2:
The patent changes the power source parameter from mains voltage (unstable) to battery voltage (stable and controllable). This parameter change ensures consistent power delivery to the heating elements, resolving the temperature stability issue while maintaining heating capability.
2Temperature
If a dry block uses fan cooling with air channels, then cooling capability is achieved, but temperature stability deteriorates due to air leakage
Solution Approach 1:
The patent removes the fan and air channel system from the dry block design. By extracting this cooling mechanism, the patent eliminates the source of air leakage and temperature instability. The cooling capability is instead achieved through passive heat dissipation or alternative methods that do not compromise temperature stability.
3Adaptability or versatility
If multiple separate calibrators are used for different fieldbus protocols, then protocol-specific calibration capability is achieved, but device complexity increases
Solution Approach 1:
The patent integrates multiple fieldbus protocol support (HART, Profibus, Foundation Fieldbus) into a single dry block device. This multi-functional design allows the same device to calibrate instruments supporting different protocols, eliminating the need for multiple separate calibrators and reducing overall device complexity.
Solution Approach 2:
The patent combines multiple protocol-specific calibration functions into one unified device. By merging HART, Profibus, and Foundation Fieldbus capabilities into a single dry block, the patent reduces the number of devices needed while maintaining comprehensive protocol calibration capability.
4Temperature
If a dry block reaches very high temperatures for calibration, then calibration range is expanded, but safety hazards increase
Solution Approach 1:
The patent incorporates temperature monitoring and control systems that provide feedback to prevent the dry block from reaching dangerously high temperatures. This feedback mechanism ensures the calibration range is sufficient for industrial applications while maintaining safety by automatically controlling temperature levels.
Solution Approach 2:
The patent implements safety features and temperature control measures beforehand to prevent hazardous temperature levels. By preparing control mechanisms and safety systems in advance, the patent ensures that even when high temperatures are needed for calibration, safety hazards are mitigated through pre-established protective measures.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution reduces the need for multiple devices, enhances safety with temperature monitoring, and simplifies calibration processes by providing a portable, versatile tool capable of handling various calibrations, including temperature and pressure, with automated documentation and reduced equipment burden.
Implementation Method 1
In a high-temperature dry block, resistive heaters are typically used to heat the calibrator block
Implementation Method 2
In a low-temperature (staying below +150 °C) dry block, Peltier elements (i.e. thermoelectric coolers, TECs) can be used to heat and cool the dry block
Implementation Method 3
a fan is used cool down the calibrator block
Data Source
Figure 1
AI summary
The present invention combines the functionalities of a multifunctional process calibrator (12) with a heating and/or cooling unit (22) (also called as a dry block). The heating and/or cooling unit (22) and the process calibrator (12) are integrated in a single housing forming the arrangement (11). The arrangement (11) allows using several digital communication protocols i.e. fieldbus protocols. Temperature sensor simulation is possible as well. Pressure measurement and/or calibration is also enabled. The arrangement is supplied with internal rechargeable battery (17), which enables all other functionalities without mains power, except the use of the heating and/or cooling unit (22), where the mains power is required.