Shut-Off Valve State-Variable Validation for Sensor Error Correction
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Solution Overview
Problem
Shut-off devices for fluids face challenges in ensuring safe, reliable, and failure-free operation, particularly when used for control purposes, due to potential errors in state variable detection and measurement inaccuracies.
Innovation Solution
A computer-implemented method using a mathematical model to describe the physical relationships between state variables, allowing for detection of errors by calculating corrected values and replacing incorrect recordings, thereby maintaining accurate operation even with defective sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If state variables are measured using sensors in the shut-off device, then operation control is enabled, but measurement errors and detection inaccuracies occur
Solution Approach 1:
The patent implements feedback by continuously monitoring state variables (pressure, temperature, flow rate) and comparing measured values against expected ranges and relationships. The control unit receives feedback from sensors and adjusts operations or triggers alarms when deviations are detected, ensuring reliable operation despite measurement uncertainties.
Solution Approach 2:
The patent applies preliminary action by establishing expected relationships and ranges for state variables before operation begins. The system pre-defines valid operating zones and inter-variable relationships, allowing it to proactively detect measurement errors by comparing real-time data against these pre-established criteria.
2Measurement precision
If multiple sensors are used to measure state variables, then measurement accuracy can be improved through redundancy, but device complexity increases
Solution Approach 1:
The patent introduces an intermediary evaluation layer that processes sensor data without requiring redundant sensors. The control unit acts as an intermediary, using algorithms to cross-validate measurements against physical relationships and operational constraints, achieving error detection with minimal sensor infrastructure.
Solution Approach 2:
The patent replaces mechanical redundancy (multiple physical sensors) with computational methods. Instead of using multiple sensors to vote on the correct value, the system uses mathematical models and relationship-based validation to detect and correct measurement errors, substituting computational complexity for hardware complexity.
3Reliability
If error detection methods are implemented in the shut-off device, then operational safety is improved, but control system complexity increases
Solution Approach 1:
The patent implements self-service error detection where the control system monitors its own operational parameters and detects errors autonomously. The shut-off device evaluates its own state variables against predefined relationships, enabling self-diagnosis without external monitoring systems, thus improving safety with minimal added complexity.
Solution Approach 2:
The control unit serves multiple functions: it controls the shut-off operation, processes sensor data, detects measurement errors, and triggers safety responses. By making the control unit multi-functional, the patent avoids adding separate dedicated error detection hardware, thereby improving operational safety without proportionally increasing system complexity.
Data Source
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AI summary
A computer-implemented method (100) for operating a shut-off device (1) for a fluid is presented and described. The method comprises a housing (2) that carries the fluid, an inlet opening (3a) for the fluid, and an outlet opening (3b) for the fluid, both provided in the housing (2). It also includes a flow channel (4) for the fluid formed in the housing (2) between the inlet opening (3a) and the outlet opening (3b). A locking device (5) is arranged in the flow channel (4) and has an adjustable flow cross-section for the fluid in the locking device (5) and thus in the flow channel (4). A control and evaluation unit (8) is included for controlling the locking device (5) and for acquiring state variables of the shut-off device (1). Increased safety and reliability of the shut-off device (1) is achieved by monitoring the relationship between at least two state variables of the shut-off device (1).between which a physical dependency exists, is described as a mathematical model (9) of the shut-off device (1), that values for the state variables are recorded at the shut-off device (1), and that at least one of the following procedure steps is carried out: - check (103) the consistency of the values of the state variables by inserting the values of the state variables into the mathematical model (9), and if an inconsistency is detected, signal (106) the presence of a recording error in the state variables, - check (104) a state variable for the presence of a recording error when recording the value of the state variable by: calculating a calculated value for the state variable to be checked by inserting the values for the other state variables into the mathematical model (9),Calculate calculated values for the other state variables by inserting the calculated value for the state variable to be checked and the values of the other state variables into the mathematical model; signal (107) a detection error in the state variable being checked if the calculated value of the state variable to be checked differs from the detected value of the state variable to be checked and the calculated values of the other state variables do not differ from the corresponding detected values of the other state variables; replace (105) the detected value of the state variable in which a detection error has occurred with a corrected value by: calculating a calculated value for the state variable in which a detection error has occurred by inserting the values for the other state variables into the mathematical model (9), and replacing the detected value for the state variable in which a detection error has occurred.through the calculated value for this state variable.