Virtual Sensor Diagnostics for Sealed EGR Components
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Solution Overview
Problem
In systems like internal combustion engine EGR systems, it is challenging to measure characteristics such as pressure and temperature between sealed components like the metering valve and the cooler due to accessibility issues, making it difficult to diagnose which component is operating improperly.
Innovation Solution
The implementation of virtual sensors using mathematical models that correlate data from upstream and downstream measurements to calculate the state of common components, allowing for the determination of system conditions without direct physical sensors in inaccessible areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensors are positioned in sealed areas between the metering valve and cooler, then measurement precision is improved, but device complexity and ease of manufacture worsen due to required system dismantling
Solution Approach 1:
The patent creates virtual sensor copies that replicate the functionality of physical sensors in inaccessible sealed areas. Mathematical models generate virtual sensor outputs based on data from accessible locations, eliminating the need to physically install sensors in sealed components between the metering valve and cooler.
Solution Approach 2:
The patent introduces mathematical models as intermediary elements that mediate between accessible physical sensors and the inaccessible measurement points. These models process data from upstream and downstream locations to infer conditions in the sealed intermediate area without direct physical access.
2Measurement precision
If physical sensors are installed in inaccessible locations, then measurement precision is improved, but loss of time increases due to system dismantling and reassembly
Solution Approach 1:
The patent performs preliminary actions by developing and implementing virtual sensor models before any physical system dismantling would be required. The mathematical models are established upfront to continuously provide measurement data without requiring future interventions or system disassembly.
Solution Approach 2:
Virtual sensor copies provide continuous measurement capability without requiring physical installation in inaccessible locations, eliminating the time-consuming cycle of dismantling, installing, and reassembling physical sensors.
3Ease of operation
If virtual sensors using mathematical models are implemented, then ease of operation is improved, but device complexity increases due to model implementation
Solution Approach 1:
The mathematical models serve multiple functions simultaneously: they process data from multiple sensors, generate virtual sensor outputs, diagnose component conditions, and predict failures. This multi-functionality justifies the added complexity by providing comprehensive system monitoring and diagnostic capabilities.
Data Source
AI summary
A system may include virtual sensors representative of operation of different portions of a tangible system. The virtual sensors may receive measured characteristics of the tangible system and may separately output values representative of operation of a common component of the tangible system based on the one or more measured characteristics input into each virtual sensor. A controller may receive the output values from the virtual sensors and determine a state of the common component by comparing the first output value with the second output value.