Pressure Transmitter with Multiple Reference Sensors
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Solution Overview
Problem
Differential pressure transmitters in fluid process control applications face limitations in measurement range and reliability, particularly when absolute or gauge pressure sensors fail, or when pressures exceed selected measurement ranges, leading to potential system failures.
Innovation Solution
Employing a plurality of absolute or gauge pressure sensors in conjunction with a differential pressure sensor to enhance measurement accuracy and reliability, and implementing diagnostic methods to estimate failed sensor outputs based on remaining sensor readings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single differential pressure sensor is used, then the device complexity is reduced, but the reliability deteriorates when the sensor fails or operates outside measurement range
Solution Approach 1:
The patent divides the pressure measurement function into multiple independent sensors: a differential pressure sensor and multiple absolute/gauge pressure sensors. Each sensor operates independently, so failure of one does not compromise the entire system. The segmentation allows the system to maintain functionality by using remaining sensors to estimate pressure values.
Solution Approach 2:
The patent implements redundancy by including multiple absolute/gauge pressure sensors before any failure occurs. This cushioning arrangement ensures that if the differential pressure sensor fails or operates outside its range, the system can immediately switch to using the redundant sensors to estimate pressure values, preventing system failure.
2Reliability
If multiple absolute or gauge pressure sensors are employed in conjunction with a differential pressure sensor, then the reliability improves, but the device complexity increases
Solution Approach 1:
The absolute/gauge pressure sensors serve multiple functions: they can independently measure pressure, they can be used to estimate differential pressure when the differential sensor is unavailable, and they provide diagnostic information about system status. This multi-functionality justifies the added complexity by providing redundant capabilities.
Solution Approach 2:
The patent uses the multiple pressure sensors to monitor system status and provide feedback about sensor health and measurement validity. The control system continuously evaluates sensor readings and switches between different sensor configurations based on real-time feedback, optimizing reliability while managing complexity.
3Measurement precision
If a single pressure sensor is used for differential pressure measurement, then the measurement precision for differential pressure is maintained, but the ability to determine line pressure deteriorates
Solution Approach 1:
The absolute/gauge pressure sensors provide the additional capability to measure line pressure independently, while the differential pressure sensor maintains its specialized function for differential pressure measurement. This universality allows the system to adapt to different measurement requirements and provides backup capabilities.
Data Source
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AI summary
Reliability and accuracy in a pressure measurement transmitter are provided by employing a plurality of absolute or gauge pressure sensors (220, 222, 230, 232; 307, 301) operating in conjunction with a differential pressure sensor. A method (400) is also provided to perform diagnostics based upon the readings of the three pressure sensors. Further, should one of the three pressure sensors (218, 220, 222, 230, 232; 301, 307, 334) fail, a reasonable estimate of process pressure beijig measured by the failed sensor can be generated based upon the remaining two sensors.