In-Situ Calibration of Physical Units Using a Virtual Process Copy
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Solution Overview
Problem
Existing calibration methods for physical units require removal from the process environment, leading to plant shutdowns and reduced efficiency.
Innovation Solution
A method that calibrates physical units in situ by creating a virtual component in a digital replica of the real process environment, using a verification unit to determine an offset and apply compensation data for accurate measurements without physical intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the physical unit is removed from the process environment for calibration, then measurement accuracy is improved, but plant productivity deteriorates due to shutdowns
Solution Approach 1:
The patent creates a virtual copy (digital twin) of the physical measurement unit and its process environment. This virtual replica allows calibration operations to be performed on the copy rather than the actual physical unit, thereby maintaining plant productivity while achieving calibration accuracy through virtual testing and validation before applying corrections to the real system.
Solution Approach 2:
The system performs preliminary calibration actions in the virtual environment before implementing changes in the physical system. By simulating calibration scenarios, determining offsets, and validating compensation data in the virtual model first, the system ensures measurement accuracy is improved while avoiding unnecessary plant shutdowns.
2Measurement precision
If the physical unit is removed from the process environment for calibration, then measurement accuracy is improved, but time consumption increases
Solution Approach 1:
By using a virtual replica of the physical unit, calibration operations can be performed instantly in the digital environment without the time-consuming physical removal, transport, and reinstallation processes. The virtual calibration maintains accuracy while eliminating calibration downtime.
Solution Approach 2:
The system enables continuous calibration operations in the virtual environment while the physical unit remains in operation. The calibration process becomes continuous rather than periodic and interruptive, as virtual calibration can be performed at any time without stopping the physical process.
3Productivity
If compensation data is applied to calibrate the physical unit in situ, then plant productivity is improved, but measurement precision may deteriorate without proper verification
Solution Approach 1:
The system uses the virtual replica to generate feedback about the expected impact of compensation data before applying it to the physical unit. By comparing virtual and physical measurements and using the virtual environment to predict calibration outcomes, the system ensures measurement precision is maintained while improving productivity through in-situ calibration.
Solution Approach 2:
The virtual environment performs preliminary verification of compensation data before it is applied to the physical system. This preliminary action in the virtual model ensures that the compensation data will improve rather than degrade measurement precision, allowing confident in-situ calibration that maintains accuracy while boosting productivity.
Data Source
AI summary
A method of calibrating a physical unit and a system for calibrating and adjusting a physical unit. The physical unit is arranged in a real process environment. A virtual component is provided in a virtual process environment formed to correspond to the real process environment so that the physical unit behaves in a manner corresponding to the virtual component. A measurement is performed with the physical unit to obtain a real measured value. A measurement is simulated with the virtual component to obtain a virtual measured value. An offset is determined by a verification unit based on a comparison of the real and virtual measured values. The real and virtual measured values are corresponding. The physical unit is calibrated by the verification unit using the offset at least such that compensation data based on the offset is taken into account for future measured values of the physical unit.