Optical Process Sensor Interface for Certified Calibration Access
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Solution Overview
Problem
Process sensors used in harsh environments face challenges in validation and calibration due to inaccessible optical beam paths, necessitating the use of certified standards which is not feasible with existing solutions.
Innovation Solution
An optical process sensor with a detachable measuring head and optical-mechanical interface allows decoupling of the measuring head from the process sensor, enabling the use of certified cuvettes or filters for validation and calibration by replacing the measuring head with a validation adapter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the beam path is protected from the harsh process environment, then the reliability of the optical components is improved, but the ease of operation for validation and calibration deteriorates
Solution Approach 1:
The optical process sensor is divided into separate functional modules: a sensor unit containing the light source and receiver, and a measuring head containing the beam path and optical elements. This segmentation allows the measuring head to be removed from the protected sensor unit for validation and calibration purposes, while the sensor unit remains protected during operation.
Solution Approach 2:
The beam path and measuring head are extracted as a separate removable component from the protected sensor housing. This extraction enables the optical path to be accessed for validation and calibration with certified standards without exposing the sensitive optical components in the sensor unit to the harsh process environment.
2Ease of operation
If the measuring head is removed from the process for validation, then the ease of operation for calibration is improved, but the productivity of the process deteriorates
Solution Approach 1:
The system is segmented into a permanent measuring head that remains in the process and a removable sensor unit. The measuring head contains all necessary optical paths and elements for validation, allowing calibration to be performed by simply attaching a validation adapter to the removed sensor unit, without disturbing the installed measuring head.
Solution Approach 2:
A validation adapter is designed as a copy or replica of the measuring head interface, containing duplicate optical paths and elements. This copying allows validation and calibration to be performed on a separate unit that replicates the measurement conditions, eliminating the need to remove the actual measuring head from the process.
3Measurement precision
If standard validation procedures are used, then the measurement precision is improved, but the device complexity increases
Solution Approach 1:
The measuring head and sensor unit interface is designed with universal coupling mechanisms that work for both process measurement and validation modes. The same optical-mechanical interfaces are used for normal operation and for connecting certified standards, eliminating the need for separate validation equipment and reducing overall system complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables complete validation and calibration of process sensors using certified standards, ensuring accurate functionality without exposing sensitive optics to harsh conditions.
Implementation Method 1
a first optical guide, wherein the first optical guide is configured such that transmitted light is guided from the light source into the first path via the first optical guide
Implementation Method 2
a second optical guide, wherein the second optical guide is configured such that received light couples into the interior of the housing and is guided from the second path to the light receiver via the second optical guide
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 2c~2d
AI summary
The invention discloses an optical process sensor (1), in particular a spectrometer, for measuring at least one quantity of a medium in a container, comprising: a housing (2); a light source (3) in the housing (2) for emitting transmitted light (5); a light receiver (4) in the housing (2) for receiving received light (6);and a first opto-mechanical interface (10) comprising a first optical section (11) projecting from the housing (2), with a first path (12) and a first light guide (13), wherein the first light guide (13) is configured such that transmitting light (5) is guided via the first light guide (13) from the light source (3) into the first path (12), and transmitting light (5) is coupled out of the housing (2), and with a second path (14) and a second light guide (15), wherein the second light guide (15) is configured such that received light (6) couples into the interior of the housing (2) and is guided via the second light guide (15) from the second path (14) to the light receiver (4), and a first mechanical section (21) configured as an integral part of the housing (2). The invention also discloses a measuring head (51), an optical measuring system (100) comprising the two, and a method.