Universal Simulation Device for Sensor Signal Generation
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Solution Overview
Problem
Current simulation devices are limited in their ability to universally simulate various sensors and adapt to different automation solutions, requiring extensive parameterization and often cannot generate realistic signals for testing safety-critical processes, such as those in piston compressors, where simulating exceptional situations like extreme accelerations or wear is challenging without risking damage to the equipment.
Innovation Solution
A simulation device with signal generating and processing means that can produce output signals mimicking physical sensors, allowing for parameterization of signal shape, amplitude, and frequency, and automatic generation of base signals based on limit and threshold values, enabling it to simulate a wide range of sensors and generate realistic signals for testing monitoring systems in automation solutions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a simulation device uses fixed signal generation methods, then the device structure remains simple, but the adaptability to simulate various sensor types and automation solutions is limited
Solution Approach 1:
The simulation device is designed with universal signal generating means and signal processing means that can handle multiple sensor types through parameterization. The device can simulate different sensor characteristics (acceleration, position, speed, temperature, pressure, flow, level, torque, force, vibration, rotational speed, angular position, linear position) by configuring signal parameters such as shape, amplitude, and frequency, making a single device capable of replacing multiple specialized simulation devices.
Solution Approach 2:
The simulation device utilizes parameter changes to achieve versatility. By modifying signal parameters (shape, amplitude, frequency, phase position) and sensor-specific parameters (sensitivity, offset, noise characteristics), the device can adapt to simulate various sensor types and automation solutions without requiring structural changes, thus maintaining simplicity while enhancing adaptability.
2Adaptability or versatility
If extensive parameterization is required to adapt the simulation device to different automation solutions, then the adaptability improves, but the ease of operation deteriorates
Solution Approach 1:
The simulation device incorporates pre-configured signal templates and automatic parameter import functions that allow users to quickly adapt to different automation solutions. The device can automatically generate appropriate signal parameters based on imported automation solution data, reducing the manual parameterization effort while maintaining high adaptability.
Solution Approach 2:
The simulation device includes feedback mechanisms that automatically adjust signal parameters based on the characteristics of the automation solution being simulated. The system can import configuration data from the target automation solution and automatically configure the signal generating means and signal processing means, significantly reducing manual parameterization work while maintaining adaptability.
3Measurement precision
If the simulation device generates realistic signals for safety-critical processes, then the measurement precision improves, but the device complexity increases due to additional signal processing requirements
Solution Approach 1:
The signal processing means utilizes parameter changes to generate realistic sensor signals by modifying base signals with sensor-specific characteristics. Through parameterization of signal shape, amplitude, frequency, and sensor-specific parameters (sensitivity, offset, noise), the device can accurately simulate various sensor types and their responses to exceptional situations without requiring complex hardware modifications.
Solution Approach 2:
The simulation device replaces physical sensor systems with software-based signal processing. Instead of using actual sensors that would require physical installation and handling, the device generates realistic sensor signals through digital signal processing of base signals, substituting mechanical/physical systems with computational approaches that reduce hardware complexity while maintaining signal realism.
4Reliability
If the simulation device tests exceptional situations like extreme accelerations or wear, then the reliability of testing improves, but the ease of operation worsens due to the complexity of setting up test scenarios
Solution Approach 1:
The simulation device enables preliminary configuration of exceptional test scenarios through parameterization. Users can pre-define test scenarios with specific signal parameters (shape, amplitude, frequency) and sensor characteristics (sensitivity, offset, noise) that represent exceptional situations such as extreme accelerations or wear conditions. This allows reliable testing of safety-critical processes while simplifying the setup process through structured parameter configuration rather than complex physical arrangements.
Solution Approach 2:
The simulation device creates copies of actual sensor signals and test scenarios through parameterization. By configuring signal parameters and sensor-specific parameters to match real-world exceptional situations, the device can replicate test scenarios without requiring physical presence of the actual equipment or dangerous conditions, thereby improving reliability while maintaining ease of operation through virtual replication.
Data Source
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AI summary
The invention relates to a simulation device (10), to a method for operating a simulation device (10), and to a use of a simulation device (10) and a method for operating a simulation device (10). The simulation device (10) is characterized in that an output signal (12), the phase position of which can be influenced, can be generated on at least one output channel (14) with a high degree of flexibility, which is achieved by an extensive parameterizing ability, such that a monitoring device (74) can be checked using the simulation device (10). One or more such output signals (12) are fed to said monitoring device instead of measured values which are normally sensed from a monitored technical process (70).