Camera-Based Virtual Sensor Validation for Process Control
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Solution Overview
Problem
Physical transmitters in chemical processes, such as petrochemical plants, are prone to failures and inaccuracies, leading to incorrect process control and potential system shutdowns, necessitating alternative measurement validation methods.
Innovation Solution
A method and system that utilize camera-based virtual sensors to validate actual sensor readings by calculating deviations and determining trusted sensor readings based on comparisons with related sensors, ensuring accurate process control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If physical transmitters are used to obtain measurements of process parameters, then process control can be implemented, but the measurements may be inaccurate or incorrect due to transmitter failures
Solution Approach 1:
The patent creates a virtual copy of the physical transmitter by using computer vision technology to capture images of the process parameter display and extract measurement data from these images. This virtual sensor reading serves as a backup and validation mechanism to verify the accuracy of the physical transmitter measurements, thereby resolving the contradiction between reliability and measurement precision.
Solution Approach 2:
The patent introduces an image processing system as an intermediary between the physical transmitter and the process control system. This intermediary captures images of the parameter display, processes them to extract measurement values, and compares these values with the physical transmitter readings, providing a validation layer that ensures measurement accuracy while maintaining system reliability.
2Measurement precision
If alternative measurement methods are introduced to validate transmitter readings, then measurement accuracy improves, but system complexity increases
Solution Approach 1:
The patent makes the camera-based virtual sensor multi-functional by using it not only to capture process parameter readings but also to provide backup measurements and validate physical transmitter readings. This universal approach allows a single additional device to perform multiple functions, improving measurement accuracy without proportionally increasing system complexity.
Solution Approach 2:
The system implements self-validation by comparing the virtual sensor readings with the physical transmitter readings automatically. The system serves itself by detecting discrepancies and triggering alerts or switching to alternative measurements without requiring external intervention, thereby improving measurement accuracy while keeping the control logic manageable.
Data Source
AI summary
A method for process control with process measurements validation capability involves obtaining a first actual sensor reading of a process variable from a field sensor to be monitored, and obtaining a first virtual sensor reading of the process variable from a virtual sensor. The virtual sensor is camera-based. The method further involves calculating a first deviation between the first actual sensor reading and the first virtual sensor reading, making a first determination that the first deviation exceeds a prespecified threshold, based on the first determination, making a second determination that the first actual sensor reading does not correspond to first related sensors readings, and based on the second determination, making the first virtual sensor reading a first trusted sensor reading for controlling an aspect of a process associated with the process variable.