Wireless Alignment Head Mesh Networking for Metal Interference
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Solution Overview
Problem
Conventional alignment head systems face reliability issues in data transmission due to direct point-to-point wireless connections, which can be disrupted in environments with abundant metalwork, such as ships or oil rigs, limiting their effectiveness in aligning larger machines.
Innovation Solution
The alignment head system employs mesh networking technology, allowing alignment heads to act as routers and forward data packets through other heads to the data acquisition device, creating a robust and reliable wireless mesh network that can self-heal and maintain connectivity even in challenging industrial environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If direct point-to-point wireless connections are used for data transmission between alignment heads and data acquisition device, then the system structure is simple, but the reliability of data transmission deteriorates in environments with abundant metalwork
Solution Approach 1:
The patent introduces intermediate wireless routers that relay data packets between alignment heads and the data acquisition device. When a direct connection is blocked by metalwork, data can be transmitted through multiple hops via these intermediary devices, ensuring reliable communication in challenging industrial environments without requiring a complete system redesign
Solution Approach 2:
The system dynamically selects transmission paths based on real-time connection quality and environmental conditions. The mesh network topology allows data to be routed through different paths depending on which nodes have clear line-of-sight, adapting to changing conditions in the industrial environment to maintain reliable transmission
2Reliability
If mesh networking technology is implemented with multiple routing paths, then the reliability of data transmission is improved, but the device complexity increases
Solution Approach 1:
The mesh network implements automatic routing protocols where each node independently determines the optimal path for data transmission. The system self-configures and self-heals when nodes are added or removed, eliminating the need for manual network configuration and reducing operational complexity despite the increased structural complexity of the mesh topology
Solution Approach 2:
The wireless routers in the mesh network serve multiple functions: they act as data relays, perform error correction, manage network topology, and provide security protocols. This multi-functionality consolidates what would otherwise require separate dedicated devices into single integrated units, reducing overall system complexity
3Reliability
If alignment heads forward data from other alignment heads, then the reliability of data exchange is improved in obstructed environments, but the data transmission protocol complexity increases
Solution Approach 1:
The patent combines the data forwarding function with the existing alignment data collection and transmission functions in a unified protocol. Alignment heads that receive alignment data also simultaneously forward it to the data acquisition device, merging two operations into one protocol implementation rather than requiring separate dedicated forwarding devices or protocols
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach ensures reliable data exchange and improved accuracy in alignment data transmission, enabling the alignment of larger machines by providing multiple paths for wireless traffic and bridging gaps where direct connections are obstructed, thus enhancing the system's robustness and reliability.
Implementation Method 1
at least one of which comprises a laser configured to generate a laser beam which emanates from the respective laser alignment head
Data Source
AI summary
An alignment head system (1, 31) for taking alignment data with respect to a pair of shafts (4, 5) coupled to each other by means of a coupling (6) comprises a data acquisition device (11) configured to wirelessly receive data, and alignment heads (2, 3). Each alignment head (2, 3) is configured to take alignment data with respect to the shafts (4, 5), to wirelessly send the alignment data to the data acquisition device (11), and to forward alignment data received from the other alignment head (2, 3).