Virtual Sensor Templates for Real-Time Fault Detection
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Solution Overview
Problem
Current statistical process monitoring systems in manufacturing face delays in detecting faults due to time-consuming data collection, analysis, and the need for restarting software applications, which hinders real-time fault detection and preventive maintenance.
Innovation Solution
The method involves creating virtual sensors using templates, allowing for real-time data processing and analysis through a statistical process monitoring system that automatically selects and configures virtual sensor templates, enabling immediate fault detection and action without requiring software restarts or extensive data acquisition processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If data collection and analysis are performed using traditional statistical process monitoring systems, then fault detection accuracy is improved, but response time deteriorates due to significant processing delays
Solution Approach 1:
The system pre-processes and stores sensor data in optimized formats during normal operation, preparing it for rapid analysis. Virtual sensors are pre-configured with analysis algorithms so that when faults occur, the system can immediately query pre-prepared data structures rather than collecting and processing raw data in real-time, thus maintaining high detection accuracy while reducing response time.
Solution Approach 2:
The patent creates virtual sensors that are computational copies of physical sensors, implementing the same measurement functions through software algorithms. These virtual sensors can process and analyze data without the physical constraints of actual sensor hardware, enabling faster fault detection while maintaining the same measurement precision as physical sensors.
2Adaptability or versatility
If new virtual sensors are created or updated in traditional systems, then monitoring capability is improved, but system availability deteriorates due to required software restarts
Solution Approach 1:
The system implements dynamic loading of virtual sensor modules, allowing new virtual sensors to be created, modified, or updated without restarting the entire software application. The virtual sensor framework supports hot-swapping of sensor modules, where changes are applied to running systems through dynamic memory allocation and module insertion, maintaining system availability while improving monitoring capability.
Solution Approach 2:
The patent segments the monitoring system into independent virtual sensor modules that can be individually created, updated, or removed. Each virtual sensor operates as a separate functional unit within the larger system, allowing modifications to specific sensors without affecting the entire application, thus maintaining high system availability while enhancing monitoring versatility.
3Manufacturing precision
If complex data preprocessing and transformation are performed, then analysis quality is improved, but processing speed deteriorates
Solution Approach 1:
The system performs data preprocessing, filtering, and transformation operations in advance during normal operation, storing pre-processed results in optimized data structures. When analysis is needed, the system queries these pre-prepared structures rather than performing complex transformations in real-time, maintaining high analysis quality while significantly improving processing speed.
Solution Approach 2:
The patent applies different levels of preprocessing and transformation only where and when needed based on local data characteristics and analysis requirements. Rather than uniformly processing all data at high quality levels, the system selectively applies complex transformations only to specific data streams requiring detailed analysis, maintaining necessary analysis quality while improving overall processing speed.
Data Source
AI summary
A method and apparatus for automatically providing a virtual sensor have been described. In one embodiment, a method for automatically providing a virtual sensor includes receiving a plurality of virtual sensor templates from a server. The method further includes selecting a virtual sensor template from the plurality of virtual sensor templates. The selected virtual sensor template has an algorithm to provide a desired functionality. The method further includes selecting at least one parameter to configure the selected virtual sensor template. The method further includes automatically creating a virtual sensor associated with the selected virtual sensor template.