Virtual Sensor

Often in industrial systems/process the prohibitive physical conditions or high cost of sensors can cause difficulties in performing physical measurements. In these cases, it is possible to identify the desired measurement from others measures available in the system/process applying the DVS® technology.

The DVS® technology applications given back successful results in: virtual measurement robustness, fault detection, recovery of physical sensor breakdowns, availability measurment in different operating conditions, sensors cost reduction for series production.

icon-mechatronicVirtual sensors for nonlinear sideslip angle estimation


Purpose: Development of a virtual sensor (DVS®) in order to provide nonlinear sideslip angle estimation which is not currently available on production cars; Nonlinear estimation of sideslip angle is needed for a better vehicle dynamics management. This technology uses input variables only measured by standard Electronic Stability Control (ESC) sensors.

Value:  Robustness of estimation accuracy vs. variability of road grip (wet or dry), road type (racetrack, urban or extra-urban), drive style (sport or normal) and tire wear; vehicle stability performances are improved in cornering control, traction control and lateral dynamics; the DVS substitutes expensive devices which cannot be used in production cars.

Patent Pending N° TO2014A000631


ico-downloadMilanese, M., Gerlero, I., and Novara, C., “Effective Vehicle Sideslip Angle Estimation using DVS Technology,” SAE Technical Paper, Detroit, 2014-01-0084, 2014, doi: 10.4271/2014-01-0084.

 SAE 2014 World Congress & Exhibition – Modelway’s presentationico-download


icon-mechatronicVirtual sensors for nonlinear engine temperature estimation


Purpose: Development of a virtual sensor (DVS®) in order to provide nonlinear estimation for oil temperature of the Multi Air actuator internal combustion engine. The  real-time measurements required are engine rpm and engine water temperature. 

Value:  Robust estimation of oil temperature is obtained. The DVS can be used for watchdogging and On-Board Diagnostic (OBD) solutions. It can also substitute expensive and frail physical sensors.


icon-mechatronicVirtual sensors for nonlinear temperature compensation


Purpose: Development of a virtual sensor (DVS®) in order to provide nonlinear temperature compensation for inline measuring system, applied on high-speed machining for ballscrew production. This kind of compensation is needed to estimate the pitch and P.C.D. ballscrew measurements at ambient temperature. The required real-time measurement are temperature of the piece worked part (hot temperature), temperature of the piece cold part (ambient temperature) and measurement of the piece dimensions in hot temperature conditions.      

Value: The DVS mean estimation error is <1μm, against a measurement system resolution 0.1μm. This solution allows to have an improvement of the real-time optimization system for a systematic nonlinear temperature compensation software tool has been developed to be embedded in the machine measuring system.


icon-mechatronic Virtual sensors for comfort estimation


Purpose: Development of a virtual sensor (DVS®) in order to provide comfort estimation in a building. The experimental data are measured by physical sensors, portable sensors and from an App available for the users. The input variables taken in considerations are temperature, lighting, air quality, noise and crowding.

Values: The virtual sensor can be used to improve the comfort in a wide range of environment, such as cars, planes and trains. It can reduce the energy management cost of a building and can substitute the physical sensors.


ico-automotiveFurther R&D Activities

After treatment systemsevery_system_integrated

  1. DVS for On-Board Diagnostic (OBD) systems.
  2. DVS for nonlinear estimation of exhaust gas temperature and composition in emission monitoring and control systems.


  1. DVS for nonlinear estimation of batteries State of Charge (SOC), State of Health (SOH) and Core Temperature.


Others virtual sensing projects where DVS® technology has been applied are:

  • Fuel composition estimate (AUTOMOTIVE).
  • Avionic physical sensors reduction (AEROSPACE).
  • Fault detection of avionic sensors (AEROSPACE).
  • Nonlinear estimation of thermal energy consumption (ENERGY & ENVIRONMENT).