Automated Non-Linear Sensor Calibration via Multi-Point Pressure
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Solution Overview
Problem
Current safety critical systems, such as medical devices, face challenges in accurately calibrating non-linear measurement systems due to manual calibration procedures, which are cumbersome and prone to inaccuracy, especially at extreme measurement ranges, leading to inconsistent and unreliable pressure readings.
Innovation Solution
An automated calibration method and apparatus that generate precise pressure values at multiple calibration points, using a known good pressure sensor to establish a mathematical relationship between measured and actual pressure values for an uncalibrated sensor, enabling precise calibration across the entire measurement range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual calibration procedures are used with two-point calibration, then the calibration process is simple to perform, but measurement precision deteriorates due to non-linearity and operator error
Solution Approach 1:
The patent replaces manual mechanical calibration operations with an automated calibration device that mechanically generates precise pressure values. The system substitutes operator-dependent manual procedures with an automated mechanism that can precisely control and reproduce pressure calibration points, thereby improving measurement precision while maintaining ease of operation through automation.
Solution Approach 2:
The patent changes the calibration approach from two-point linear calibration to multi-point calibration with non-linear parameter adjustment. By measuring at multiple pressure points and establishing non-linear relationships between sensor output and actual pressure values, the system compensates for sensor non-linearity and improves measurement accuracy across the entire measurement range.
2Measurement precision
If automated calibration with multiple calibration points is implemented, then measurement precision improves, but device complexity increases
Solution Approach 1:
The patent introduces a known good pressure sensor as an intermediary reference standard to bridge the calibration process. This intermediary device provides accurate reference pressure measurements that enable the calibration of the primary sensor without requiring direct access to precision pressure generation equipment, thereby improving measurement precision while managing system complexity through the use of a reliable reference standard.
3Ease of operation
If manual pressure generation is used for calibration, then ease of operation is maintained, but reliability deteriorates due to inconsistent pressure generation
Solution Approach 1:
The patent replaces manual mechanical pressure generation with an automated calibration device that mechanically generates pressure through controlled mechanisms. This substitution eliminates operator variability and inconsistency, ensuring reliable and repeatable pressure calibration points while maintaining ease of operation through automated control and execution.
Data Source
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AI summary
A method and system for calibrating an analog sensor used in a digital measurement system is provided. The design comprises generating a precise pressure value set at multiple calibration points and supplying said precise pressure value set to an uncalibrated pressure sensor, detecting sensor changes for the uncalibrated pressure sensor based on each precise pressure value generated, polling an actual pressure reading associated with a sensor change for the uncalibrated pressure sensor for each calibration point, and establishing a mathematical relationship between measured value readings and actual pressure for the uncalibrated sensor. Establishing the mathematical relationship converts the uncalibrated sensor to a newly calibrated sensor. A known good sensor may be employed to enhance calibration reliability.