Infrared Thermal Imaging Diagnostics for Automated Process Anomaly Detection
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Solution Overview
Problem
Existing methods for monitoring industrial processes for leaks and anomalies, such as temperature gradients, require manual interpretation with handheld thermal imaging cameras, which is time-consuming and lacks continuous monitoring.
Innovation Solution
A diagnostic field device equipped with an infrared sensor array and processing circuitry that generates thermal images and compares outputs from multiple subsections to identify anomalies, allowing for automated detection of leaks and other thermal diagnostic conditions without operator intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual interpretation with handheld thermal imaging cameras is used, then detection capability is achieved, but time consumption and lack of continuous monitoring occur
Solution Approach 1:
The patent replaces the manual mechanical inspection process with an automated electronic system. Fixed thermal imaging cameras capture thermal images continuously, and a processor automatically analyzes temperature distributions to detect leaks, eliminating the need for operators to manually walk through facilities with handheld devices.
Solution Approach 2:
The system implements continuous monitoring by permanently installing thermal imaging cameras at fixed locations that continuously capture thermal images of process areas. The processor continuously analyzes these images to detect temperature anomalies indicating leaks, providing uninterrupted surveillance rather than periodic manual inspections.
2Reliability
If manual interpretation methods are used, then leak detection is possible, but continuous monitoring capability is lost
Solution Approach 1:
The patent replaces manual inspection with an automated system where thermal imaging cameras and processors continuously monitor temperature distributions. The system automatically detects leaks through algorithmic analysis of thermal images, eliminating reliance on human operators and enabling uninterrupted surveillance.
Solution Approach 2:
The system performs self-diagnosis by automatically analyzing thermal images to detect temperature anomalies indicating leaks. The processor independently identifies diagnostic conditions without requiring human intervention, allowing the system to monitor itself and alert operators only when anomalies are detected.
3Extent of automation
If automated infrared sensor arrays are deployed, then continuous monitoring is achieved, but device complexity increases
Solution Approach 1:
The system divides the monitoring task into separate functional modules: thermal imaging cameras capture images, processors analyze temperature distributions, and the system identifies diagnostic conditions. This segmentation allows each component to perform its specific function efficiently while working together as an integrated automated monitoring system.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables continuous, automated monitoring of industrial processes for leaks and anomalies, reducing the likelihood of false detections and allowing for timely intervention in critical situations.
Implementation Method 1
an infrared sensor array having a plurality of infrared sensors arranged to sense infrared emissions from a location in the industrial process
Data Source
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AI summary
A diagnostic field device (12) for identifying a diagnostic condition in an industrial process (10) includes an infrared sensor array (100) having a plurality of infrared sensors arranged to sense infrared emissions (104) from a location (32) in the industrial process (10). Processing circuitry (102) processes outputs from the plurality of infrared sensors of the sensor array (100) and generates an infrared image. Diagnostic circuitry (24) compares processed outputs from at least two subsections of the infrared image and provides a diagnostic output based upon the comparison.