Compact Wireless Sensor Layout for Shock-Resistant Machine Monitoring
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Solution Overview
Problem
Existing wireless sensors for machines are large, prone to failure under high shock or vibration, and have limitations with traditional wireless protocols, making them unsuitable for many applications.
Innovation Solution
A compact, robust wireless sensor with a communications module that collects, stores, and transmits data related to machine properties, featuring control circuitry, a motion sensor, and optional magnetic and RFID components, optimized for low power consumption and customizable transmission intervals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing commercial sensors use traditional wireless protocols and standard designs, then they can transmit data wirelessly, but they become large in size and prone to failure under high shock or vibration
Solution Approach 1:
The sensor is divided into separate functional modules: a sensing element module and a communications module. The sensing element can be a simple piezoelectric crystal or strain gauge that converts physical quantities directly to electrical signals, while the communications module handles all wireless communication functions. This segmentation allows the sensing portion to be minimal and robust, while the complex communication functions are isolated in a separate module that can be optimized independently.
Solution Approach 2:
The patent employs modern wireless communication protocols and techniques that differ from traditional approaches. It uses packet-based communication with configurable data rates, implements error correction codes, and employs efficient modulation schemes that are more resilient to vibration and shock. The communication module can adapt its operating parameters (data rate, power level, protocol selection) based on environmental conditions, maintaining reliable transmission in harsh environments where traditional protocols would fail.
2Use of energy by moving object
If existing commercial sensors are designed for robustness, then they can withstand shock and vibration, but they consume more power and have limited transmission capability
Solution Approach 1:
The communications module operates in periodic cycles rather than continuously. It collects data from the sensing element, buffers multiple readings, and transmits them in periodic bursts at optimized intervals. This periodic operation allows the microcontroller and radio to enter low-power sleep modes between transmissions, dramatically reducing average power consumption while maintaining reliable data transmission. The transmission interval can be configured based on the application requirements and battery capacity.
Solution Approach 2:
The system implements acknowledgment-based communication where the receiving device sends confirmation signals back to the sensor. This feedback mechanism ensures that data was successfully received and transmitted reliably. The sensor can detect transmission failures and automatically retry or alert the user, maintaining high data transmission reliability even with reduced power consumption. The feedback loop allows the system to optimize its operation based on actual communication success rates.
Data Source
AI summary
A wireless sensor for an associated machine or machine part which includes a communications module that wirelessly transmits data related to the associated machine or machine part. The communications module is mounted on the sensor and the sensor is disposed under the bottom side of the control circuitry. A sensor is configured to measure one or more properties of the associated machine or machine part.