For most industrial scenarios, the combined algorithm of phased dynamic threshold + 3σ adaptive update + EWMA baseline compensation is the most reliable. It balances the three core requirements of low false alarm rate, ease of implementation, and long-term stability, resulting in significantly higher reliability than other single algorithms.
Why is this combination the most reliable?
Adapting to operating condition fluctuations and resolving 80% of common false alarms: Phased dynamic thresholds automatically adapt to different process states such as injection molding, cooling, and start-up/shutdown, preventing false alarms triggered by instantaneous shocks/vibrations, making it far more reliable than fixed thresholds.
Automatically adapting to sensor aging and ensuring good long-term stability: 3σ updated thresholds + EWMA baseline compensation slowly follow the aging drift of sensors, preventing a surge in false alarm rates due to baseline offset after six months of use. Long-term operational reliability is a level higher than fixed dynamic thresholds.
Low implementation difficulty, can run on ordinary PLCs: It does not require the high computing power and large amount of training data of machine learning. Factory electrical engineers can directly configure and debug it, avoiding instability due to algorithm complexity, resulting in a near 100% success rate in implementation.
Reliability priority adjustments for different scenarios:
For simple retrofits in small to medium-sized factories with limited budgets: Choosing "phased dynamic thresholds + delayed confirmation" offers significantly higher reliability than fixed thresholds, with extremely low development costs, sufficient for most needs.
For high-end medical/aerospace scenarios with extremely high reliability requirements: Adding machine learning anomaly detection for secondary verification further improves reliability, but costs also increase accordingly.
For continuous production in pure process industries: EWMA baseline compensation has higher priority, offering better long-term reliability than phased thresholds.
Currently, the mainstream global hot runner dual-sensor systems all use this combination solution, with over 10 years of industrial deployment and verification, maintaining a false alarm rate stably below 3%. It represents the best balance between cost-effectiveness and reliability currently available.
