Sensor Plausibility Verification for Drift Detection in Plant Processes
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Solution Overview
Problem
Existing methods for verifying sensor information in plant processes, such as water treatment, are inadequate in detecting drifting sensor readings, which can lead to inefficient operation and non-compliance with quality requirements, especially since interval-based calibration is cumbersome and may miss issues between scheduled comparisons.
Innovation Solution
A method involving a control unit that uses a verification model to compare received sensor information with expected information based on other plant process-related data, such as second sensor readings, process parameters, or control activities, to output a verification signal when discrepancies are found, allowing for event-based calibration and ensuring accurate sensor operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If interval-based comparison/calibration of sensor devices is performed, then sensor accuracy can be maintained at scheduled intervals, but the method is cumbersome and time/resource consuming, and drifting sensor readings occurring between successive comparisons cannot be identified
Solution Approach 1:
The system implements continuous feedback by comparing sensor readings against expected values derived from process models and other sensor data. This real-time feedback mechanism automatically detects drifting sensor readings without requiring manual intervention or scheduled calibration intervals, thus maintaining measurement precision while eliminating time loss associated with periodic calibration.
Solution Approach 2:
The sensor verification system performs self-service by automatically detecting its own drift conditions through cross-validation with process models and other sensors. The system identifies when calibration is needed and can trigger automated calibration routines, eliminating the need for external scheduling and manual calibration operations.
2Reliability
If sensor devices are calibrated according to a given time interval, then sensor accuracy can be maintained, but the procedure is cumbersome and drifting sensor readings between calibrations cannot be identified
Solution Approach 1:
Continuous feedback loops compare sensor readings with expected values from process models and other sensor measurements in real-time. This automated verification system maintains sensor reliability by immediately detecting drift conditions without requiring complex scheduled calibration procedures, thereby simplifying the overall system while improving reliability.
Solution Approach 2:
The patent replaces the mechanical/manual calibration system with an automated electronic verification system. Instead of physically accessing and calibrating sensors at scheduled intervals, the system uses electronic data processing to continuously verify sensor readings against process models and other sensor data, automatically identifying when calibration is needed.
3Productivity
If sensor information is used continuously for control without verification, then process control can be maintained, but faulty sensor readings can cause inadequate control actions and inefficiency
Solution Approach 1:
The verification system implements continuous feedback by comparing sensor readings against expected values derived from process models and other sensor measurements. This feedback mechanism maintains both productivity and reliability by ensuring that only verified, accurate sensor information is used for control decisions, preventing inadequate control actions while maintaining continuous operation.
Solution Approach 2:
The system performs preliminary verification of sensor readings before they are used for control actions. By pre-validating sensor information against process models and other sensors, the system ensures that only reliable data drives control decisions, maintaining productivity while preventing the negative effects of faulty sensor information.
Data Source
AI summary
An aspect of the invention relates to a method for verifying the plausibility of sensor information sensed by a sensor device associated with a plant process, in particular a water treatment process and/or a wastewater treatment process, wherein the sensor information relates to the plant process, the method comprising: receiving (S100), by a control unit, the sensor information; performing (S110), by the control unit, a verification model, the verification model determining an expected sensor information which the sensor device shall provide, wherein the verification model determines the expected sensor information based on at least one other information related to the plant process and having a relationship to the sensor information; comparing the expected sensor information with the received sensor information; and upon determining (S120) that the sensor information deviates from the expected sensor information, outputting (S130), by the control unit, a verification signal.