Impact of Accuracy on Industrial Production
Accuracy refers to the closeness of the collected value to the real value, which determines whether the data is reliable and the control is precise.
- Inaccurate temperature, pressure, flow, and liquid level → errors in formulation, reaction, and proportioning.
- For process-sensitive industries such as chemical, heat treatment, coating, injection molding, food and beverage:A 0.5% accuracy deviation may lead to batch rejection, color difference, substandard hardness, and unqualified composition.
- Low accuracy → PLC/controller receives "false data" → over-adjustment or under-adjustment.
- Performance: oscillation, overshoot, large fluctuation, frequent start-stop of equipment, and increased energy consumption.
- Inaccurate collection of pressure, temperature, and flammable gas concentration
→ failure to alarm or false alarm
→ potential safety hazards and losses caused by unnecessary shutdown.
- Deviations in statistics of flow, energy consumption, and raw material consumption
→ distorted cost accounting, inaccurate energy consumption analysis, and disputes over trade settlement.
- Data drift and large errors → invalidation of MES and big data analysis.
- Failure to conduct trend prediction, fault early warning, and process optimization.
Impact of Sampling Rate on Industrial Production
Sampling rate refers to the number of data collected per second, which determines whether rapid changes can be captured.
- Impact, vibration, instantaneous pressure spike, current surge, valve action
→ too low sampling rate → direct omission.
- Consequence: failure to find the cause of faults and recessive equipment damage.
- Motion control, high-speed filling, flying shear, tension control
→ slow sampling → control lag → increased reject rate and inaccurate positioning.
- Motor current, vibration, hydraulic system
→ low sampling rate only shows a "straight line", while high sampling can identify harmonics, impacts, and abnormal fluctuations.
- Basis for predictive maintenance: bearing wear, gear failure, and insulation aging are identified by high-frequency sampling.
- Higher sampling rate → larger data volume
→ increased pressure on storage, transmission, and cloud.
→ The higher the better is not applicable; adequacy is sufficient.