Liquid Level Sensor Fault Detection via Pattern Analysis
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Solution Overview
Problem
Existing fault detection techniques for liquid level sensing devices, such as resistive-type sensors with multiple reed switches, fail to accurately identify dormant faults as they may output voltage values within the operational range despite mechanical or electrical errors, leading to inaccurate oil level measurements.
Innovation Solution
A computer-implemented fault detection method and system that analyzes sensing signals from liquid level sensing devices to determine if the liquid level changes follow expected patterns, outputting a fault signal if an abnormal change pattern is detected, thereby identifying faulty switches and ensuring accurate measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If voltage value checking within predetermined operational range is used for fault detection, then the detection process is simple, but dormant faults in switches cannot be accurately identified
Solution Approach 1:
The system performs preliminary actions by analyzing the sequence and pattern of switch actuations before making a fault determination. Instead of simply checking voltage values, the system pre-establishes expected actuation patterns and compares actual switch behavior against these patterns to detect dormant faults early.
Solution Approach 2:
The system implements feedback by continuously monitoring switch actuation patterns and comparing them against expected patterns. When deviations are detected, the system provides feedback through fault indicators to alert operators of potential issues, enabling continuous improvement of detection accuracy.
2Measurement precision
If multiple switches are used in the liquid level sensing device, then measurement coverage is improved, but the complexity of fault detection increases
Solution Approach 1:
The control unit serves multiple functions: it monitors liquid level measurements from multiple switches, analyzes actuation patterns, detects faults, and provides diagnostics. This multi-functionality allows the system to maintain high measurement precision while managing detection complexity through a single integrated control unit.
Solution Approach 2:
The system merges the monitoring and analysis functions into a unified process. Instead of separate systems for each switch, the control unit combines all switch signals and analyzes them collectively using pattern recognition, reducing overall system complexity while maintaining accurate multi-point measurement capability.
3Productivity
If traditional voltage range checking is performed, then processing time is reduced, but accurate fault identification is compromised
Solution Approach 1:
The system performs preliminary analysis of switch actuation patterns continuously in the background, so when a fault condition arises, the identification can be made rapidly based on pre-established pattern recognition rules, maintaining both speed and reliability.
Solution Approach 2:
The system dynamically adjusts its analysis based on the specific actuation patterns observed. Rather than using fixed thresholds, the system adapts its fault detection criteria based on the sequence and timing of switch activations, enabling reliable fault identification while maintaining efficient processing.
Data Source
AI summary
A system and a method for fault detection for a liquid level sensing device are provided. The liquid level sensing device comprising a plurality of switches arranged to measure variance in a liquid level. A sensing signal comprising a plurality of measurements indicative of the liquid level is received from the liquid level sensing device. Each measurement is obtained in response to one or more of the plurality of switches being in a given position at a given liquid level. It is determined, based on the sensing signal, whether the liquid level changed according to one or more expected change patterns. A fault signal is output in response to determining that the liquid level changed according to an abnormal change pattern.