Higher-Level Virtual Sensors Using Simulation Lookup Datasets
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Solution Overview
Problem
Conventional methods for providing virtual sensors in industrial automation systems are limited by long processing times, expertise requirements, and inability to operate in real-time, especially when complementing physical sensors on higher-level machine platforms.
Innovation Solution
A method that generates a dataset using simulation models to correlate physical sensor measurements with virtual sensor output values, allowing for real-time operation on higher-level machine platforms without the need for complex solvers, using a standard format like the Functional Mock-up Interface (FMI) and simple knowledge representations like lookup tables or linear functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional simulation models are used to create virtual sensors, then measurement data can be obtained without physical sensors, but processing time becomes excessively long (hours to days)
Solution Approach 1:
The patent pre-calculates and stores simulation results in lookup tables during an offline phase, so that during real-time operation, only a simple table lookup is needed instead of running full simulations. This preliminary preparation eliminates the time-consuming computation during actual measurement.
Solution Approach 2:
The patent creates a simplified copy of the simulation model in the form of lookup tables that replicate the simulation results. Instead of executing the complex original simulation model in real-time, the system uses these pre-generated table copies that provide the same measurement data instantaneously.
2Speed
If physical sensors are installed on machine components, then real-time measurement data can be obtained, but the measurement process influences and disturbs the actual industrial process
Solution Approach 1:
The patent introduces simulation models as an intermediary between the physical system and the measurement requirement. Instead of directly measuring with physical sensors that disturb the system, the simulation model acts as a mediator that computes measurement values based on process data without physically interacting with or disturbing the industrial process.
Solution Approach 2:
The patent creates a virtual copy of the physical system through simulation models. This digital replica allows measurement of process parameters without the need for physical sensors in the actual system, thereby eliminating the harmful influence of sensor installation and operation on the industrial process.
3Measurement precision
If complex simulation models are used for virtual sensors, then comprehensive measurement data can be obtained, but the system becomes difficult to operate and requires expert knowledge
Solution Approach 1:
The patent segments the complex simulation model into discrete lookup tables that can be easily stored and queried. This segmentation transforms the complex continuous simulation into discrete, manageable table structures that are simple to implement and operate without requiring deep simulation expertise.
Solution Approach 2:
The patent creates simplified table-based copies of complex simulation models. These table copies retain the essential measurement capabilities while removing the operational complexity of running full simulations, making the system accessible to non-experts through simple lookup operations.
4Measurement precision
If physical sensors are repositioned or recalibrated, then accurate local measurements can be obtained, but complex readjustment and recalibration are required
Solution Approach 1:
The patent uses virtual sensor copies that can be repositioned in the simulation model without any physical movement or recalibration. Changing the measurement location simply involves modifying the simulation model parameters, which is computationally instantaneous and requires no manual intervention, unlike physical sensor repositioning.
Solution Approach 2:
The simulation model automatically recalculates measurement values when parameters change, without requiring manual recalibration procedures. The system self-adjusts to new measurement conditions through automatic recomputation, eliminating the need for expert intervention in recalibration processes.
Data Source
AI summary
The invention relates to a method for providing a virtual sensor in an automation system of an industrial system. A measurement value of a physical sensor, said measurement value corresponding to a physical parameter of the industrial system, is received in a processing device of the automation system. A data set which has been generated using a simulation model is provided in the processing device, wherein the data set produces a unique relationship between possible measurement values of the physical sensor and corresponding output values of the virtual sensor. The data set and the received measurement value are used to determine which output value of the virtual sensor belongs to the received measurement value (20), and said output value is then displayed on a display device of the industrial system.