Controller Mediates Data Exchange for Calibration Without Downtime
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing measurement data acquisition systems require significant time and technical effort for maintenance and calibration of measuring devices, often necessitating system downtime and requiring expensive hardware, as technicians need direct access to each device for calibration and maintenance.
Innovation Solution
A method for data transmission between measuring devices and a data processing device that allows for continuous operation of the system, where the controller acts as an intermediary between different protocols, enabling digital communication and calibration during ongoing monitoring by using a predetermined time interval for exchange steps and a shift memory to buffer messages, ensuring efficient data packet processing without interrupting the system's operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If direct connection between data processing device and measuring device is established for maintenance and calibration, then communication and calibration can be performed, but system downtime occurs and technical effort increases
Solution Approach 1:
The controller serves as an intermediary between the data processing device and the measuring device. Instead of requiring direct connection between the laptop and measuring device, all communication is routed through the controller which manages the exchange of data packets, enabling maintenance operations without physical reconnection of measuring devices.
Solution Approach 2:
The communication process is segmented into distinct phases: normal operation mode where the controller periodically queries measuring devices, and maintenance mode where the controller facilitates direct communication between the data processing device and specific measuring devices. This segmentation allows maintenance operations to occur without taking the entire system offline.
2Ease of operation
If direct connection between data processing device and measuring device is established, then calibration can be performed, but expensive special hardware is required
Solution Approach 1:
The controller performs multiple functions: it acts as a normal operational query interface for periodic measuring device monitoring, and simultaneously serves as a communication gateway for maintenance operations. This multi-functionality eliminates the need for separate specialized hardware for calibration, as the existing controller handles both operational and maintenance communication needs.
Solution Approach 2:
The communication protocol implemented through the controller creates a virtual direct connection between the data processing device and measuring device. Instead of requiring physical direct connection with specialized hardware, the controller copies and forwards communication packets, creating a logical equivalent of direct connection using standard communication interfaces.
3Ease of repair
If measuring devices are disconnected from the system for maintenance, then individual device calibration is possible, but the entire measuring system must be taken out of operation
Solution Approach 1:
The system maintains continuous operation during maintenance activities. The controller continues to receive and process measurement data from all measuring devices throughout the maintenance process. Only the specific measuring device being calibrated is temporarily paused for communication, while the rest of the system operates uninterrupted, ensuring continuous useful action.
Solution Approach 2:
The controller acts as a mediator that manages communication during maintenance operations. It receives calibration commands from the data processing device and forwards them to the target measuring device while simultaneously continuing to receive operational data from all measuring devices. This mediation enables individual device maintenance without system-wide shutdown.
4Reliability
If controller continuously exchanges data with all measuring devices, then monitoring operation continues, but additional communication load is created during maintenance operations
Solution Approach 1:
During normal operation, the controller exchanges data with measuring devices at predetermined periodic intervals rather than continuously. This periodic exchange reduces the communication load and energy consumption while maintaining reliable monitoring. The periodic nature allows time windows to be identified for inserting maintenance communication without increasing overall load.
Solution Approach 2:
The communication protocol dynamically adjusts its behavior based on operational mode. During normal monitoring, it uses periodic lightweight exchanges. During maintenance operations, it switches to a different mode where communication is concentrated in specific time windows when the controller can handle additional data packets from the data processing device without overwhelming the system.
Data Source
Figure 1
Figure 2
AI summary
A method for data transmission between measuring devices (5) and a data processing device (3, 3') in a measurement data acquisition system (1, 1') is presented and described, the method comprising: Repeated execution of exchange steps by the controller (7, 7'), wherein an exchange step comprises receiving analog measurement signals from the measuring devices (5) and/or digitally exchanging digital messages between the measuring devices (5) and the controller (7, 7'), and wherein the exchange steps are initiated at a predetermined time interval; Sending a digital data packet by the data processing device (3, 3') to the controller (7, 7'), wherein the digital data packet contains the identifier of one of the plurality of measuring devices (5) and a digital message; Extracting the identifier from the digital data packet by the controller (7, 7').7') and sending the digital message to one of the multiple measuring devices (5) by the controller (7, 7') after completion of the digital exchange.