Control System Hardware Verification Using Optical Module Markings
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Solution Overview
Problem
Existing control and data transmission systems with modular designs face challenges in determining the correct connection of control and evaluation modules to I/O modules due to identical connection geometries, leading to potential malfunctions.
Innovation Solution
A method using a mobile device with a camera to capture and compare digital images of a real control system with a stored digital representation, utilizing optical markings like barcodes or QR codes to identify and verify the correct hardware configuration of control and I/O modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If optical markings are applied at predetermined locations on control and I/O modules, then hardware configuration verification accuracy is improved, but device complexity increases
Solution Approach 1:
The patent uses optical markings (barcodes, QR codes, data matrices) as visual copies of identification information that can be captured by a camera. These markings encode module identifiers and connection information, allowing the system to verify hardware configuration by comparing captured images against stored reference data, thereby improving verification accuracy without requiring complex electronic identification systems.
Solution Approach 2:
The patent replaces manual visual inspection and physical verification methods with an automated optical recognition system. The camera-based image capture and automated comparison process substitutes for manual checking, reducing human error and improving verification precision while the software handling manages the complexity of the automated system.
2Reliability
If manual inspection of hardware configuration is performed, then device complexity is kept low, but verification time increases and reliability decreases
Solution Approach 1:
The system enables self-service verification where the control system automatically captures images of optical markings, processes the identification information, and verifies hardware configuration without requiring manual intervention. The automated comparison of captured images against stored reference data provides reliable verification results quickly, eliminating the time-consuming and error-prone manual inspection process.
Solution Approach 2:
The patent implements a feedback mechanism where the camera captures the actual hardware configuration, the system processes the optical marking information, compares it with the expected configuration, and provides immediate verification results. This closed-loop feedback system ensures high reliability by automatically detecting configuration errors and alerting operators, while the rapid processing minimizes verification time.
3Loss of information
If optical markings are used for identification, then information accuracy is improved, but manufacturing cost increases
Solution Approach 1:
The patent uses inexpensive optical markings (barcodes, QR codes, data matrices) that can be printed or applied to control and I/O modules during manufacturing. These optical copies of identification information provide accurate module identification and connection data that can be read by standard camera devices, achieving high information accuracy without requiring expensive RFID tags, NFC components, or other costly electronic identification systems.
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
Enables quick, reliable, and simple verification of the control system's hardware configuration, preventing incorrect assembly and potential malfunctions by ensuring correct connection and deactivating the system if faults are detected.
Implementation Method 1
capturing, with the camera of the mobile device, a digital image of the actual control system
Data Source
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AI summary
The invention relates to a method for checking the hardware configuration of a real control system (10) by means of a mobile apparatus (90), which contains a camera (91) and a memory apparatus (92) in which a digital representation of a desired hardware configuration of the control system (10) is stored. Now a digital image of a real control system (10) is captured, which system comprises a control module having a plurality of connection apparatuses, an I/O module being connected to each connection apparatus such that the control module is mechanically coupled to the I/O modules, an optical marking for uniquely identifying the control module being applied to the control module and an optical marking for uniquely identifying the I/O module in question being applied to each I/O module. Thereafter, the hardware configuration of the real control system (10) is checked in the mobile apparatus by comparing the digital representation stored in the mobile apparatus (90) with the captured digital image using the optical markings.