Particle Sensor Calibration Using a Moving Contrast Plate
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Solution Overview
Problem
Particle sensors based on optical measurement methods face accuracy issues due to contamination on optical paths or changes in laser parameters, requiring complex recalibration that is often impossible during field use.
Innovation Solution
A method involving a calibration plate with contrast regions in a calibration plane, where a laser beam is focused to generate a calibration intensity distribution, and the plate is moved to simulate particle movement, allowing the sensor to be calibrated by recording and evaluating intensity signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If optical measurement methods are used for particle sensing, then particle characterization capability is improved, but measurement accuracy deteriorates due to contamination and parameter changes
Solution Approach 1:
The patent creates optical copies (virtual images) of calibration particles using a projection element. These virtual images are formed in the measurement volume and detected by the sensor, allowing calibration without physical particles in the measurement path. This copying approach eliminates contamination issues while maintaining measurement accuracy.
Solution Approach 2:
The patent introduces a projection element as an intermediary device that generates virtual particle images. This intermediary allows calibration to be performed remotely by projecting patterns onto the measurement volume, avoiding direct contact between calibration materials and the measurement path, thus preventing contamination.
2Measurement precision
If recalibration is performed to maintain measurement accuracy, then measurement precision is improved, but system complexity increases
Solution Approach 1:
The projection element creates virtual images of calibration particles, eliminating the need for physical calibration particles in the measurement volume. This simplifies the recalibration process by using optical projections instead of complex particle introduction systems.
Solution Approach 2:
The system performs self-calibration by using its own optical components (projection element) to generate calibration signals. The calibration process is integrated into the existing sensor system, allowing the sensor to calibrate itself without external complex equipment.
3Ease of operation
If field recalibration is enabled, then ease of operation is improved, but device complexity increases
Solution Approach 1:
The projection element generates virtual calibration particle images that can be displayed in the measurement volume during field operation. This allows operators to perform calibration remotely using optical projections, improving ease of operation without requiring complex physical calibration setups.
Solution Approach 2:
The projection element serves multiple functions: it can project calibration patterns for calibration operations and can potentially display other visual information during normal operation. This multi-functionality reduces the need for separate dedicated calibration equipment, balancing ease of operation with acceptable device 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 accurate calibration of particle sensors, enabling remote diagnosis and recalibration without disrupting operation, and improves measurement accuracy across various particle sizes and materials.
Implementation Method 1
focusing a laser beam on a calibration plane for generating a calibration intensity distribution in the calibration plane
Implementation Method 2
Contrast regions for modulating an intensity of the laser beam are formed on the calibration plate
Data Source
AI summary
A method for calibrating a particle sensor includes focusing a laser beam on a calibration plane for generating a calibration intensity distribution in the calibration plane. A calibration plate is arranged in the calibration plane. Contrast regions for modulating an intensity of the laser beam are formed on the calibration plate. The method further includes moving the calibration plate and/or the calibration intensity distribution in the calibration plane, recording at least one intensity signal of the laser beam, following passage through the calibration plane, and calibrating the particle sensor by evaluating the at least one intensity signal.