Simulation of Virtual Redundant Sensor Models for Safety-Related Applications

Applications of safety-related control systems demand reliable and credible inputs from physical sensors, therefore there is a need to extend their capabilities to provide a validated input with high availability. Our main idea is to insert virtual sensors between physical sensors and the control system’s logic. The created solution can validate the values of real sensors and with the use of multiple virtual sensors we can achieve high availability in addition, therefore our solution is entitled as a virtual redundant sensor. It works by the digital twin’s concept and uses fusion function to calculate validated results. The fusion function is used to transform the measured values from the physical sensors according to designed numerical models. The selection of a numerical model with assigned fusion functions can be performed via the WEB-based graphical user interface. Proposal of the numerical model is created and validated on the experimental workplace with emulation of physical sensors and MQTT integration (smart IoT sensors). The results of testing have shown that our solution can be applied to validate the values of physical sensors. Proposed fusion functions calculated results according to the selected model in all cases, while non-standard cases were handled according to our definition. In addition, the high availability concept with a group of two virtual sensors has proven fast recovery and availability of results for safety-related applications as well