International

Carpathian Control
Conference ICCC’ 2002
MALENOVICE,
CZECH REPUBLIC
May 27-30, 2002

THE SYSTEMS OF INDIRECT MEASUREMENT

Karol KOSTÚR
Department of Applied Informatics and Control Processes,
Faculty of BERG, Technical University of Košice,
Slovak Republic, Karol Kostur@tuke.sk

Abstract: The some variables are not direct measured, because there are not suitable
sensors available. Therefore in world are permanently developed various methods for its
measurements. In paper is described some methods for indirect measurement. Their using
improve the quality of control system. Very often for example the temperature of charge
(controlled variable) in industry furnace is not controlled but the temperature of combustion
of products is measured and by help this information is controlling of heating.

Key words: the types of indirect measurement, models for indirect measurement, the
structure of models.

1 Introduction
The problem of indirect measurement is not a new, but it is by interest of technical
professional workers still. This problem is topical if we have to control a variable or
variables, which are not measured. Usual, the reason of unmeasured variable does not exist
suitable sensors. Similar the cases in technological praxes are often. We describe some
cases. The aim of control of heating charge in industry furnaces is to obtain required
temperature of charge. The heating of moving charge is controlled by change of heat
power.

∆u, (τ ) = f (e,τ ) (1)

where τ - is the time,
u – is the control input,
e( τ ) – is the deviation of control

63
 and

e(τ) = t r (τ) − t m (τ) (2)

where tr – is the required temperature of charge,
tm – is the measured temperature of charge.

The measured temperature of charge is unknown usually because by thermocouple it

to measure is impossible (the moving of charge). The measurement this temperature is
unreliable by using of pyrometer. The reason is in the changes of optical and radiation
properties in industry furnaces during of measurement. Therefore, the real control systems
use instead of relationship (2) following relationship (3)

c(τ) = t cr (τ) − t cm (τ) (3)

where
t cr - is the required temperature of combustion products,
t cm - is the measured temperature of combustion products by thermocouples.
Then these control systems do not control the temperature of charge but they control
the temperature of combustion of products in industry furnaces. Of course it is qualitative
different in controlling process.

2 The Types of Indirect Measurement

The aim of indirect measurement systems as well as is known “Input direct a
measured variable/variables to transform on an unmeasured variable/variables”.

x y
Ot

Figure 1. The principal of indirect measurement

On Figure 2 is shown the principal scheme of system for indirect measurement. The x
is output variable from some sensor and y is the indirect measured variable. The operator of
transformation Ot can be in simple form but sometime it is very complicated functions.

We can divide the systems of indirect measurement to three groups :

a) First type is transformation x (τ) → y (τ)

b) Second type is transformation x (τ) → y (τ)

c) Third type is transformation x (τ) → y (τ)

64
2.1 First Type of Systems

This type of indirect measurement is simple and oldest. The model of

transformation operator is known as static characteristic (transfer) of sensors. For example
the output voltage from thermocouple “u” is calculated on temperature “t” according static
characteristic.

t = f (u) (4)
where transformation operator is

Ot = f (u) (5)

The development of sensors is quickly, but it is directed on improvement of

connecting I/0 devices with control system. Smart sensors [Smutný 2001] are as well as
common definitions of intelligent sensors. Of course, they do not bring a new quality of
information.

2.2 Second Type of Systems

The second type these systems provides transformation more inputs from sensors
on one indirect measured variable (see Figure 2)

x (τ) y (τ)
Ot

Figure 2. The scheme of second type of indirect measurement systems

This type is based on using of boundary conditions second type usually. The problem of
measurement the temperature of charge, which has been described in introduction, we can
solve following. It you will be to measure:

dt m
- the heat flow x 1 = −λ
dx x = h
- the temperature of combustion products in industry furnaces

x 2 = t cm ,

then is possible to calculate the temperature of charge y = tm from boundary condition

(6) and initial condition tm(0) = const.

65
 dt m
−λ = α t ( t cm − t m ) (6)
dx
at each time.
Other practical example is indirect measurement of concentration of carbon in steel
making process. For direct measured variables :

- the concentration of CO x1= % CO

- the concentration of CO2 x2 = % CO2
- the volume flow of gas x3 = V&
then we can calculate the concentration of carbon in LD converter
y=%C
from boundary condition (7) and initial condition y(0) = y0

dy
= k x 3 ( x1 + x 2 ) (7)
dτ
This type uses differential equations and difference equations.

2.3 Third Type of Systems

This type we can characterise following scheme:

x (τ + ∆τ)

x (τ) Ot y (τ)

Figure 3. The scheme of third type of indirect measurement

This type is very complicated. Without feedback loop these systems are based on solving of
partial differential equations. For example, the temperature field in some heating material
we can calculate from Fourier partial equation

 ∂t 
∂ λ 
∂ ( t.c.σ)  ∂x 
= (8)
∂τ ∂x

if boundary conditions are

66
 ∂t
−λ = q 1 ( τ) for x = 0
∂x x = 0
∂t
−λ = q 2 ( τ) for x = h
∂x x = h

t (x,o) = f (x).

Then

y ( τ) = t ( x , τ) in some coordinates

x (τ) = {q 1 (τ), q 2 (τ)}.

If you add to system some measured feedback variables from process then we can find
the model of indirect measurement in other forms. For example by experimental way has
been derived difference equations [Kostúr 2001 1,2,3,4].

Models for indirect measurement of temperature in LD converter emanate from

regression approach. Transmission functions for each process are based on measuring data.
Regression model is constructed of an equations that are described by systems difference
equations (9), where iteration loop (step by step) is calculating dependent variables Ex.

Ex1 (k + 1) = a10 + a11 ⋅ x1 (k ) + a12 ⋅ x2 (k ) + K + a1n ⋅ xn (k ) + a1n +1 ⋅ v1 (k ) + K a1n + m ⋅ vm (k )

(9)
Exn (k + 1) = an 0 + an1 ⋅ x1 (k ) + an 2 ⋅ x2 (k ) + K + ann ⋅ xn (k ) + ann +1 ⋅ v1 (k ) + K ann + m ⋅ vm (k )

where: Exi(k+1) – dependent indirect measured variable in step k+1, xi(k) – independent
measured variable in step k, vi(k) – control variable in step k, ai – regression
parameters.
On Figure 4 is shown indirect measured variable of temperature liquid steel in steel
making process. This variable is very important for control of steel making process,
because the quality of steel and following proceeding of steel dependent on this
temperature. Up to the temperature was impossible continually to measure during steel
making direct, because there are very aggressive conditions (high temperature,…)

67
 160
1600
140
1400
120

%CO, %CO2, Press [Pa]

Tbath [°C], Tcombus [°C]

1200
100

1000
80

800
60

600 40

400 20

200 0
0 100 200 300 400 500 600 700 800 900 1000
tim e [s ]
T b a th Tcom bus P re s s u re %CO %CO2

Figure 4. The courses directly measured variables and indirectly measured of

temperature

3 Conclusion
In this paper are characterised three types of models for indirect measurement.
This classification is first attempt to arrange experiences from building of systems for
indirect measurement. The meaning these models is big for creating of correct control
systems. Of course second, but very important reason is economy. The duration of melt
is approximately 15 minutes in LD converter. The time of direct measurement of
temperature is 3-5 minutes (to close blowing of oxygen, up jet, ...). If this measurement
is repeated 2 x, then the production capacity is half of total only. Therefore the development
of methods for indirect measurement has a high importance all first for technological
processes with very aggressive environment.

References

KOSTÚR, K., LACIAK, M. 2001-1. Models for prediction of LD process. In International

Carpathian Control Conference 2001. Krynica, Poland : AGH Krakow, 2001, pp. 159-
164. ISBN 83-91340-07-4
KOSTÚR, K., LACIAK, M., TRÉFA, G. 2001-2. System of indirect measurement
temperature of metal bath in converter. Research report. Košice, 2001, 128 pp.
KOSTÚR, K., LACIAK, M. 2001-3. Subsystém nepriameho merania teplôt ocele
v konveretore (1). AT&P journal 8/2001, pp. 52-53
KOSTÚR, K., LACIAK, M. 2001-4. Subsystém nepriameho merania teplôt ocele
v konveretore (2). AT&P journal 9/2001, pp. 79-81
SMUTNÝ, L., JANDA, P. 2001. Smart sensors for desplacement measurement in
mechatronics control system. In International Carpathian ControlConference 2001.
Krynica, Poland: AGH Krakow 2001, p.p. 485-490, ISBN 83-91340-07-4

68