Process Station Visual Monitoring for Gauge Deviation Detection

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Solution Overview

Problem

Existing sample conditioning systems in industrial plants are not efficiently monitored, leading to frequent operational deviations that can affect analysis system performance due to manual review being infrequent and costly digital upgrades being prohibitive.

Innovation Solution

A system that captures digital images of process stations, analyzes visual indicators, and compares them to expected states to generate indicia for deviations, enabling automated monitoring and reducing operator intervention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual review of gauges and valves is used to monitor process stations, then operational costs are reduced, but monitoring frequency and reliability deteriorate

Engineering Contradiction:

Improvemonitoring reliabilityVSAvoidmonitoring frequency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The system enables self-service monitoring by capturing images of gauges and valves, automatically analyzing visual indicators, and generating deviation reports without requiring operator intervention. The processor autonomously compares current states against expected states defined in configuration data, allowing continuous monitoring while reducing manual labor requirements.

Inventive Principle:

Principle #25Self-service

2Measurement precision

If digital measurement systems are installed at process stations, then monitoring precision is improved, but system cost deteriorates

Engineering Contradiction:

Improvemonitoring precisionVSAvoidsystem cost

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

Instead of installing expensive digital measurement systems, the patent uses digital images (copies) of the existing analog gauges and valves. The image processing system creates virtual representations of the physical indicators, extracting measurement information from visual data without requiring physical replacement of the monitoring infrastructure.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent replaces mechanical/digital measurement systems with an optical-based image processing system. By using cameras to capture images and processors to analyze visual indicators, the system substitutes traditional electronic measurement devices with a vision-based approach, achieving digital monitoring capabilities through optical means rather than mechanical or electronic sensors.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS12444197B2Monitoring process stations utilizing visual indicators

Publication Date: 2025.10.14 ABB (SCHWEIZ) AG

AI summary

In one aspect, a system includes at least one processor configured to identify a digital image of the process station generated during an operation of the process station, identify, in the digital image, a visual indicator of the process station, and analyze the visual indicator to identify a current state of the visual indicator. The at least one processor is further configured to identify configuration data for the process station that defines an expected state of the visual indicator, determine whether the current state deviates from the expected state, and generate indicia representing the identified current state in response to determining that the current state deviates from the expected state.