Mettler Toledo introduces ISM Intelligent sensor management technology

Intelligent Sensor Management reduces the installation, maintenance, and calibration effort for the new digital sensors to a minimum. This considerably improves process reliability, productivity, and system availability. The new digital sensors with ISM (Intelligent Sensor Management) technology are equipped with an integrated chip in the sensor head that stores all relevant sensor parameters and algorithms for enhanced sensor diagnostics. Plug & Measure: Simple installation and configurationThe sensor stores all relevant data to enable fast start-up when connecting the sensor to a transmitter. The sensor is automatically detected, and the system parameterizes itself. When making adjustments, for example, calibration data from the sensor is imported for adjustment purposes, and typical threshold values are set for the sensor diagnostics. The measurement signal is evaluated directly in the sensor. The measured value is transferred to the transmitter by means of a low-impedance digital signal. The measuring instrument used with the digital sensors is the modular M700 transmitter, which allows integration of up to three modules for pH/redox, oxygen, and conductivity. The system is backward- and forward-compatible, meaning that transmitters with ISM functionality can also handle conventional analog sensors.The sensors are equipped with the tried and tested K8S connector, which has IP68 degree of protection and is therefore ideally suited for harsh, humid environments. Data transfer takes place via an inexpensive coaxial cable, which can also be used to cover long distances between the sensor and transmitter due to the low impedance of the signal.Predictive maintenance The goal of Intelligent Sensor Management is to perform maintenance work only as often as necessary, i.e. to calibrate, service, and replace parts only when this is actually required. Achieving this goal requires precise knowledge of the behavior of the sensors under a wide range of process conditions. With over 50 years of experience in manufacturing quality sensors for pH and oxygen measurement, METTLER TOLEDO has developed algorithms for predictive maintenance. Actual process conditions, such as pH value, temperature, number of CIP and SIP cycles, membrane and diaphragm resistance (pH), and resistance between anode and cathode (oxygen), are monitored continuously. These values are then used to generate a wear matrix for a particular sensor. This simplifies diagnostics in the event of measurement problems, while also providing information about the timing of the next required calibration or adjustment, as well as the remaining lifetime of the sensor. As is typical with modern navigation systems, these calculations are performed dynamically.Groundbreaking maintenance concept – Plant Asset Management The new sensors can be calibrated under controlled conditions in the lab. Since the calibration data is stored in the sensor, the sensor only needs to be replaced at the measuring point location on-site. This eliminates the need to handle sensor and calibration solutions in the plant – often under unfavorable atmospheric and lighting conditions at hard-to-access measuring points. Sensors can be replaced on-site by untrained personnel, while skilled lab technicians at a central location use ISM diagnostic tools to analyze the sensors from operations to determine whether and for how long the sensors can continue to be used following cleaning, conditioning, and recalibration. In the event of measurement problems, ISM diagnostics facilitate troubleshooting.This eliminates complex configuration and parameterization operations at the measuring point as well as labor-intensive, time-consuming calibration and maintenance procedures. Measured values are more reliable and accurate, and system availability is increased – which in turn improves process reliability, yield, and quality, while reducing costs.Integration into process control systems Sensors with ISM functionality are able to generate the operating status of the measuring point according to NAMUR recommendation NE 107 and then transfer this to the process control system via a transmitter with PROFIBUS PA Profile 3.01.

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