Intelligent Cable Module Calibration Using Iterative Load Cell Link
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Solution Overview
Problem
Calibrating intelligent cable modules to accurately measure tension in tensile fiber strength members is challenging due to variations in cable designs and materials, making it difficult to develop a universal mathematical relationship between tension proxy measurements and applied tension, and requiring a practical solution for each specific cable design.
Innovation Solution
A calibration process using a separate calibration load cell that establishes a communication link with the intelligent cable module and performs an iterative series of loading cycles to create a calibration curve correlating internal measurements with actual cable tension, allowing the module to convert its measurements into useful tension values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a universal mathematical relationship is attempted for all cable designs, then the complexity of calibration is reduced, but the measurement precision deteriorates due to variations in cable designs and materials
Solution Approach 1:
The patent applies local quality by creating calibration curves specific to each cable design and material composition rather than using a universal calibration method. The intelligent cable module is calibrated individually for each cable's unique characteristics, ensuring high measurement precision while maintaining practical calibration complexity through automated iterative processes.
2Measurement precision
If individual calibration for each cable design is performed, then the measurement precision is improved, but the time and resources required for calibration increase
Solution Approach 1:
The patent implements preliminary action by performing calibration during the cable manufacturing process or initial installation phase, before the cable enters service. The iterative loading cycles and calibration curve generation are completed in advance, so that when the cable is deployed, the intelligent module is already calibrated and ready for immediate use, minimizing calibration time impact.
Solution Approach 2:
The intelligent cable module performs self-calibration through automated iterative loading cycles where the module applies known loads to itself and measures the response. This self-service calibration process eliminates the need for external calibration equipment and reduces manual intervention, significantly reducing calibration time while maintaining individualized precision for each cable design.
3Adaptability or versatility
If the cable is used in different applications over time, then the versatility is improved, but the reliability of tension measurements deteriorates due to changes in cable characteristics
Solution Approach 1:
The patent implements feedback by continuously monitoring the cable's tension measurements and comparing them against the stored calibration curve. When the cable is transferred to a different application or shows signs of characteristic changes, the system can detect deviations and trigger recalibration. This feedback mechanism maintains measurement reliability across different applications by ensuring the calibration remains valid for the current cable state.
Data Source
AI summary
A calibration process for use in calibrating intelligent cable modules. A separate calibration load cell is provided. This device is placed in the load path for the cable on which the intelligent cable module is installed. The calibration load cell then establishes a communication link with the intelligent cable module. An iterative series of loading cycles are started. Tension data as measured by the calibration load cell is used to create a calibration curve. This calibration curve is used to correlate internal measurements made by the intelligent cable module against a desired value—such as cable tension.