Actuator Diagnostic Module for Hazard Detection and Data Access
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Solution Overview
Problem
Existing diagnostic units for sensor data from actuators or machine elements lack the ability to determine hazardous states and provide actionable instructions, are often inaccessible for data reading, and require costly rewiring for retrofitting, with limited communication options.
Innovation Solution
A diagnostic unit with sensors, a data processing unit, and an interface unit connected via wired or wireless connections, capable of analyzing sensor data, determining hazardous states, and transmitting procedures to avoid such states, with an integrated power supply and wireless data transmission to controllers and display units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If diagnostic units are integrated into actuator control units, then data processing capability is improved, but accessibility for data reading deteriorates due to protected controllers
Solution Approach 1:
The patent introduces a separate diagnostic unit as an intermediary device that interfaces with the protected actuator control unit. This standalone diagnostic unit can read sensor data through the control unit's interfaces without requiring direct access to the protected controller internals, thus maintaining data processing capability while improving accessibility for data reading and analysis.
2Reliability
If diagnostic units communicate only via wired connections, then data transmission reliability is improved, but installation complexity and cost increase due to rewiring requirements
Solution Approach 1:
The diagnostic unit is designed with multi-functional communication capabilities, supporting both wired connections (for reliable data transmission) and wireless communication interfaces (for easy installation). This universal communication approach allows the system to maintain reliability through wired options while eliminating the need for complex rewiring during installation through wireless alternatives.
3Reliability
If sensor data is processed to determine hazardous states, then safety capability is improved, but computational requirements and system complexity increase
Solution Approach 1:
The patent segments the diagnostic system into modular functional components: sensor data acquisition module, data processing module for hazardous state detection, and communication module. This segmentation allows the safety-critical processing functions to be isolated and optimized independently, improving safety capability while managing system complexity through modular design that enables selective implementation based on specific application requirements.
Data Source
Figure 1
AI summary
The invention relates to a diagnosis unit (1) for detection, analysis and data management of sensor data detected on an actuator (20), wherein the diagnosis unit (1) comprises at least one sensor (14, 15), a data processing unit (10), a data manager (11) and an interface unit (12), the at least one sensor (14, 15), the interface unit (12) and the data manager (11) are respectively connected to the data processing unit (10), enabling data exchange, and the diagnosis unit (1) is built into a module with the actuator (20).