Heating System Energy Flow Simulation to Reduce Sensor Complexity
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Solution Overview
Problem
The measurement of thermal efficiency in steam heaters requires complex and costly equipment, particularly flow-rate sensors, which are not economically viable for periodic checks rather than continuous monitoring.
Innovation Solution
A system that simulates the heating process using data from supply and discharge system sensors, allowing for the determination of energy flow and consumption without the need for physical sensors, using a computer device to ascertain energy inflow, outflow, and consumption information, thereby simplifying and cost-effectively measuring energy efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If flow-rate sensors are used to measure thermal efficiency of steam heater, then measurement precision is improved, but device complexity and cost increase disproportionately
Solution Approach 1:
The patent creates a virtual copy of the flow-rate sensor functionality through software simulation in a digital twin model. Instead of using physical flow-rate sensors, the system simulates steam flow characteristics by processing data from existing temperature and pressure sensors through the digital twin model, thereby achieving measurement precision without the complexity and cost of physical flow sensors
Solution Approach 2:
The patent replaces the mechanical/physical flow-rate sensor system with a computational/software-based system. The digital twin model uses algorithms to calculate steam flow rates by processing temperature and pressure data, substituting physical sensing mechanisms with virtual computation to reduce device complexity while maintaining measurement capability
2Reliability
If flow-rate sensors are installed for continuous monitoring, then reliability of efficiency measurement is improved, but cost becomes economically unviable for periodic checks
Solution Approach 1:
The patent makes existing temperature and pressure sensors serve multiple functions: they not only monitor operational parameters for process control but also feed data into the digital twin model to calculate steam flow rates and thermal efficiency. This multi-functionality eliminates the need for dedicated flow-rate sensors while maintaining reliable efficiency measurement for both continuous monitoring and periodic checks
Solution Approach 2:
The system uses its own existing sensor infrastructure (temperature and pressure sensors) to generate efficiency measurement data through the digital twin simulation. The digital twin model processes data from sensors already installed for operational purposes, allowing the system to self-generate efficiency metrics without requiring additional dedicated measurement equipment
3Measurement precision
If extensive sensor hardware is installed to measure energy flow, then measurement precision is improved, but ease of manufacture and installation deteriorates
Solution Approach 1:
The patent creates virtual sensors within the digital twin model that replicate the measurement capabilities of physical flow-rate and energy flow sensors. These virtual sensors process data from existing temperature and pressure sensors to calculate energy flow parameters, achieving precise measurement without the complex installation and manufacturing requirements of physical energy flow sensors
Data Source
AI summary
A system includes an installation that has a heating system and a device or component, wherein the system is configured to heat the device or component via a heated medium transported within the heating system, where the heating system includes a supply system within which the heated medium is supplied to the device or component, where the supply system includes at least one supply-system sensor, the heating system includes a removal system for the medium, the removal system includes at least one removal-system sensor, and where the system includes a computer device that is configured to simulate the heating system using data from the at least one supply-system sensor and/or the at least one removal-system sensor, where the computer device is configured to ascertain energy-flow information.