Cellular Gateway Control for Remote Industrial Sensor Networks
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Solution Overview
Problem
Existing industrial monitoring systems lack wireless sensor capabilities, intermediate data storage, and efficient data transmission to remote repositories, limiting their ability to handle large datasets and provide real-time control signals for process adjustments.
Innovation Solution
A method and apparatus that utilize a gateway with wireless sensor data transmission, intermediate data storage, and cellular communication to process and analyze data from sensors, enabling control signals to be sent back to the industrial process, while also incorporating GPS, Bluetooth, and RS485 communication standards for robust and autonomous operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If wireless sensor elements and intermediate data storage are integrated into the gateway, then data transmission capability and autonomy are improved, but device complexity increases
Solution Approach 1:
The patent merges wireless sensor elements, intermediate data storage, and transmission capabilities into a single gateway device. This consolidation allows the gateway to function autonomously by collecting, storing, and transmitting data without requiring separate external components for each function.
Solution Approach 2:
The gateway is designed as a multi-functional device that can perform sensing, data storage, data processing, and communication functions. This universal design enables the single device to handle multiple tasks that would traditionally require separate specialized components.
2Measurement precision
If large datasets are accumulated at the remote repository for later analysis, then measurement precision is improved, but loss of time in data transmission increases
Solution Approach 1:
The gateway performs preliminary data processing and filtering before transmitting data to the remote repository. By pre-processing data locally, the system reduces the volume of data that needs to be transmitted while maintaining the quality and precision needed for accurate analysis.
Solution Approach 2:
The gateway acts as an intermediary between sensors and the remote repository, performing intermediate data storage and processing. This intermediate step allows data to be buffered and pre-processed locally, reducing transmission delays and bandwidth requirements while preserving data integrity for later analysis.
3Productivity
If control signals are transmitted back to the process in real-time, then productivity is improved, but device complexity increases
Solution Approach 1:
The system implements feedback by transmitting control signals from the remote repository back through the gateway to the industrial process. This closed-loop feedback mechanism enables real-time process adjustments based on analyzed data, improving productivity through automated control.
Data Source
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AI summary
The invention regards a method for monitoring and controlling an industrial process (3) which change condition over time. According to the method the following steps are performed: - add at least one remote sensor (4) to an element (5) which is part of, or affected by the industrial process (3); - collect sensor data and transmit the collected sensor data wirelessly or by wire to an intermediate data storage and data processing unit (2) hereinafter named gateway (2); - transmit processed data from the gateway (2) to a remote data storage (6) by way of a cellular device (7) and, - access the remote data storage from a location (8) and process the transmitted data further to gain knowledge of at least one condition of the industrial process (3) and, - that the cellular device (7) is accessed from the location (8) or from the remote data storage, and that instructions are routed to the gateway (2) and, that - based on the instructions, control signals (9) are produced at the gateway and routed from the gateway (2) to a control device (10) which is connected to the industrial process, and that - the control device (10) based on the control signal (9) serves a condition changing signal at the industrial process (3).