Heat Exchanger Fault Classification Using Virtual Sensor Parameters
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Solution Overview
Problem
Existing apparatuses face challenges in efficiently monitoring and troubleshooting faults due to the high cost and weight of numerous sensors, or the lack of insight into fault causes with fewer sensors, leading to inefficient maintenance activities.
Innovation Solution
A method and apparatus that utilize a control circuit, potentially including a neural network, to process sensor information from a limited number of sensors, generating virtual parameters to classify fault classes rather than individual failure modes, facilitating targeted maintenance tasks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If numerous sensors are employed to monitor different sections and operating states of the apparatus, then fault detection capability is improved, but device complexity and cost increase
Solution Approach 1:
The patent introduces a control circuit as an intermediary that processes sensor information and generates virtual parameters. This mediator enables fault detection capabilities equivalent to numerous sensors while using fewer physical sensors, as the control circuit synthesizes additional diagnostic information from limited sensor inputs through complex processing algorithms
Solution Approach 2:
The patent creates virtual parameters that copy or represent the information that would be obtained from additional physical sensors. By generating virtual sensor readings through control circuit processing, the system replicates the functionality of numerous sensors without physically installing them, thereby reducing device complexity while maintaining fault detection capability
2Device complexity
If fewer sensors are employed to reduce cost and complexity, then device complexity is reduced, but fault diagnosis insight deteriorates
Solution Approach 1:
The patent replaces the mechanical approach of adding more physical sensors with an information processing approach using a control circuit. Instead of mechanically installing numerous sensors to capture all fault information, the system uses computational processing to extract and generate diagnostic information from limited sensor inputs, substituting physical complexity with intelligent processing
Solution Approach 2:
The patent transforms the available sensor parameters into additional virtual parameters through processing in the control circuit. By changing the form and combination of parameters through computational operations, the system derives more diagnostic information than the original sensors directly provide, preventing information loss despite using fewer physical sensors
3Measurement precision
If comprehensive fault analysis is performed to identify individual failure modes, then fault diagnosis precision is improved, but maintenance time increases
Solution Approach 1:
The control circuit performs preliminary processing and classification of fault information by generating virtual parameters and determining fault classes before maintenance personnel arrive. This preliminary action pre-organizes the diagnostic information, so when maintenance is needed, the precise fault analysis is already completed, eliminating the need for time-consuming on-site troubleshooting while maintaining high diagnostic precision
4Quantity of substance
If virtual parameters are generated through control circuit processing, then sensor quantity is reduced, but processing complexity increases
Solution Approach 1:
The patent merges the functions of numerous sensors into a single control circuit that processes information from fewer physical sensors. By combining multiple sensing and processing functions into one integrated control unit, the system reduces the total number of components while the increased processing complexity is contained within a single device rather than distributed across many sensors
Data Source
AI summary
Sensor information from a plurality of sensors that monitor a heat exchanger is accessed and then sensed information that corresponds to that sensor information is input into a control circuit configured to output virtual parameters corresponding to the heat exchanger as a function, at least in part, of the sensed information. A particular fault class is determined from amongst a plurality of fault classes as a function, at least in part, of the virtual parameters and at least one task is identified regarding the heat exchanger that corresponds to the particular fault class.