Monitoring and control interface based on virtual sensors

In this article, a toolbox based on a monitoring and control interface (MCI) is presented and applied in a heat exchanger. The MCI was programed in order to realize sensor fault detection and isolation and fault tolerance using virtual sensors. The virtual sensors were designed from model-based high-gain observers. To develop the control task, different kinds of control laws were included in the monitoring and control interface. These control laws are PID, MPC and a non-linear model-based control law. The MCI helps to maintain the heat exchanger under operation, even if a temperature outlet sensor fault occurs; in the case of outlet temperature sensor failure, the MCI will display an alarm. The monitoring and control interface is used as a practical tool to support electronic engineering students with heat transfer and control concepts to be applied in a double-pipe heat exchanger pilot plant. The method aims to teach the students through the observation and manipulation of the main variables of the process and by the interaction with the monitoring and control interface (MCI) developed in LabVIEW©. The MCI provides the electronic engineering students with the knowledge of heat exchanger behavior, since the interface is provided with a thermodynamic model that approximates the temperatures and the physical properties of the fluid (density and heat capacity). An advantage of the interface is the easy manipulation of the actuator for an automatic or manual operation. Another advantage of the monitoring and control interface is that all algorithms can be manipulated and modified by the users.