Non-Invasive Sensor Validation for Accurate Process Monitoring
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Solution Overview
Problem
Existing industrial sensors face challenges in accurately measuring process parameters without direct contact, necessitating invasive installation methods and lacking reliable on-site calibration, which affects measurement accuracy and reliability.
Innovation Solution
A non-invasive sensor assembly with unique thermal, mechanical, and electrical characteristics is used, connected wirelessly to an electronics assembly, allowing for on-site calibration and validation, ensuring accurate measurements by comparing characteristic groups and adjusting for environmental conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If non-invasive sensors are used to measure process parameters, then installation complexity is reduced and process interruption is minimized, but measurement accuracy and reliability deteriorate due to lack of direct contact with the medium
Solution Approach 1:
The sensor assembly is pre-calibrated in a validation assembly before deployment to establish its characteristic group (thermal, mechanical, electrical characteristics). This preliminary calibration action ensures that even though the sensor is non-invasive and cannot be directly contact the medium, it has pre-established reference data for accurate measurement. The characteristic group is stored and can be retrieved for validation during operation.
Solution Approach 2:
The system continuously validates the sensor assembly by comparing the measured characteristic group against the pre-stored reference characteristic group. When deviations are detected (indicating sensor drift or environmental changes), the system can trigger re-calibration or adjustment. This feedback loop maintains measurement accuracy despite the non-invasive nature of the sensor.
2Measurement precision
If sensors are installed in intimate contact with process fluid for accurate measurement, then measurement accuracy is improved, but system complexity and installation difficulty increase
Solution Approach 1:
The measurement system is divided into separate functional modules: the sensor assembly (which can be easily attached to the pipe), the validation assembly (for calibration), and the electronics assembly (for signal processing). This segmentation allows the sensor to be installed non-invasively on the pipe without requiring complex integration, while the validation assembly handles the complexity of calibration separately.
Solution Approach 2:
The validation assembly acts as an intermediary between the sensor assembly and the final measurement output. It provides the calibration infrastructure and characteristic validation without requiring the sensor itself to be complex. The intermediary validation system handles the complexity of ensuring accuracy, allowing the sensor to remain simple and easy to install.
3Reliability
If on-site calibration is implemented for sensor validation, then measurement reliability is improved, but time consumption and operational complexity increase
Solution Approach 1:
The sensor assembly is calibrated in advance in the validation assembly to establish its characteristic group before being deployed to the process site. This preliminary calibration action stores reference data that can be quickly validated on-site without requiring lengthy calibration procedures during operation, thus maintaining reliability while minimizing time loss.
Solution Approach 2:
The sensor assembly performs self-validation by having its characteristic group automatically retrieved and compared against stored reference values. This self-service capability eliminates the need for manual calibration procedures during operation, maintaining high reliability while minimizing the time and operational complexity required for validation.
Data Source
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AI summary
The invention relates to a method (1) for detecting and monitoring a process (600) by means of a measuring arrangement (100) comprising a sensor assembly (110) and an electronics assembly (130), which comprises the steps of providing (20) the sensor assembly (110) for detecting a measuring value of the process (600) to be detected, connecting (30) the sensor assembly (110) to the electronics assembly (130) for transmitting the measuring value of the process (600) to be detected from the sensor assembly to the electronics assembly, allowing (40) the electronics assembly (130) retrieving a characteristic group of the sensor assembly (110) comprising a thermal characteristic and/or a mechanical characteristic and/or an electrical characteristic of the sensor assembly (110), and outputting (70), by means of the electronics assembly, the measuring value of the process (600) and/or the characteristic group of the sensor assembly (110).