Sensor Calibration System Drift Function Automation
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Solution Overview
Problem
Sensors experience gradual sensitivity drift over time due to material degradation, environmental contamination, and mechanical forces, leading to inaccurate measurements, false positives, and false negatives, necessitating inefficient and error-prone manual recalibration.
Innovation Solution
A sensor calibration system that includes a controller connected to sensors, which receives electrical outputs during specific input conditions to determine a drift function, adjusting raw sensor outputs to maintain accurate measurements, and can be semi-automated or fully automated.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual recalibration is performed to correct sensor drift, then measurement accuracy is improved, but the process is inefficient and error-prone
Solution Approach 1:
The patent replaces manual mechanical recalibration processes with an automated electronic system. The controller automatically performs calibration by sending test signals to the sensor, receiving electrical outputs, calculating drift functions, and adjusting measurement conversions without manual intervention, thereby improving efficiency while maintaining accuracy.
Solution Approach 2:
The system enables self-calibration where the controller autonomously manages the entire recalibration process. The controller automatically submits the sensor to test input conditions, processes the electrical outputs, determines drift functions, and applies corrections without requiring operator disconnection or manual adjustment, making the sensor system self-sufficient for maintenance.
2Reliability
If sensors are replaced frequently to avoid drift inaccuracies, then measurement reliability is improved, but cost and material waste increase
Solution Approach 1:
Instead of discarding drifted sensors, the system recovers their functionality through automated recalibration. The controller continuously monitors sensor performance and applies drift compensation functions to extend sensor operational life, preventing premature disposal and reducing material waste while maintaining measurement reliability.
3Measurement precision
If manual recalibration is performed, then sensor drift is corrected, but human error increases the risk of inaccuracies
Solution Approach 1:
The patent eliminates human intervention from the recalibration process by replacing manual operations with automated electronic calculations. The controller programmatically performs all calibration steps including drift function determination and measurement conversion adjustment, removing the source of human error and improving recalibration reliability.
4Measurement precision
If the sensor output conversion function is manually adjusted, then drift offset is reduced, but the process complexity increases
Solution Approach 1:
The patent merges the recalibration function into the existing controller that already manages sensor data. The controller integrates drift detection, drift function calculation, and conversion adjustment all within its existing processing architecture, avoiding the need for separate calibration equipment and simplifying the overall system.
Data Source
AI summary
A sensor calibration system includes a controller configured to receive a first electrical output generated by a sensor while submitted to a first input condition and a second electrical output generated by the sensor while submitted to a second input condition. The first and second electrical outputs represent lower and upper limits, respectively, of a sensor measurement range. The controller obtains a first reference value that corresponds to the lower limit and a second reference value that corresponds to the upper limit, and determines a drift function of the sensor based on a value of the first electrical output, a value of the second electrical output, the first reference value, and the second reference value. The controller inputs a value of a raw electrical output generated by the sensor into the drift function to determine an adjusted value of the raw electrical output.