A virtual sensor uses information available from other measurements and process parameters to calculate an estimated value of a process parameter. Consider the following scenario, A physical sensor in a grinding machine measures the speed at which the grinding wheel is spinning. As the grinding wheel meets the metal object that is ground, the grinding wheel becomes hot. For purposes of maintaining the grinding wheel, it is necessary to estimate the temperature of the grinding wheel. A virtual sensor can be developed which can algorithmically estimate the grinding wheel temperature based on the speed and the electrical current consumed by the grinding machine. A virtual sensor models a physical process to estimate a value. In this example, mechanical engineers who designed the grinding wheel know how temperature increases with increased speed and electrical current consumption. The virtual sensor implements that relationship between speed, electrical current consumption, and temperature in software.
There are numerous benefits of a virtual sensor. It does not require any physical space or does not need an energy source such as a battery. Since there are no physical components in a virtual sensor, there is no performance degradation over time. Finally, the cost of the virtual sensor is essentially one-time software development cost which will be spread across multiple instances of the virtual sensor.
Virtual sensors cannot replace physical sensors. As shown in the above example, virtual sensors depend upon physical sensors. So, we see a need for both virtual and physical sensors in coming up with innovative industrial solutions.
At Olyphaunt Solutions, we specialize in designing and developing industrial solutions with different types of sensors, Internet of Things (IoT), Artificial Intelligence and Machine Learning.
For more information, please contact us on info@olyphaunt.com