Device Condition Data Collection via Segmented Direct and Indirect Methods
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Solution Overview
Problem
Existing methods for collecting device-condition information from multiple devices in a factory or plant, such as steam traps, are inefficient due to the need for direct human intervention and high costs associated with multiple sensors and communication facilities, making it difficult to collect accurate information in a timely and cost-effective manner.
Innovation Solution
A method and kit that divide devices into direct and indirect collection groups, allowing for the use of either direct detection by a portable unit or wireless communication with stationary units, optimizing the collection method based on device type, location, importance, and trouble frequency, thereby reducing the need for extensive human intervention and lowering costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If direct collection method is used for all devices, then accurate device-condition information can be collected, but a great number of information collecting persons are required and time and costs are excessive
Solution Approach 1:
The patent segments the collection methods into two distinct approaches: direct collection method for devices requiring high accuracy (e.g., critical equipment) and indirect collection method for devices where approximate information suffices. This segmentation allows the system to allocate resources efficiently, applying manual direct collection only where necessary while using automated indirect collection for the majority of devices, thereby resolving the contradiction between measurement precision and productivity.
2Productivity
If indirect collection method is used for all devices, then information collection costs are reduced, but the system requires the same number of sensors as devices and each unit needs communication facility
Solution Approach 1:
The patent applies local quality by assigning different collection methods to different devices based on their specific characteristics, importance, and location. Critical devices located in accessible areas use direct collection with portable units, while non-critical devices in hard-to-reach locations use indirect collection. This localized approach optimizes the balance between productivity and device complexity by applying the more expensive indirect method only where necessary.
3Measurement precision
If direct collection method is used, then accurate information can be obtained, but it requires detecting operation by collecting person for each device
Solution Approach 1:
The patent introduces dynamics by making the collection method flexible and adaptable rather than static. The system can dynamically switch between direct and indirect collection methods based on device characteristics, location, and operational requirements. This dynamic approach resolves the contradiction by allowing manual direct collection when accuracy is paramount while enabling automated indirect collection when operational simplicity is prioritized.
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
This approach enables efficient and accurate collection of device-condition information by tailoring the collection method to each device's specific situation, reducing the number of personnel and costs required, while improving the frequency and timing of data collection.
Implementation Method 1
a sensor for sensing ultrasonic oscillation and temperature on an outer surface of a steam trap
Implementation Method 2
a sensor for sensing ultrasonic oscillation and temperature on an outer surface of a steam trap
Data Source
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AI summary
Accurate device-condition information of and relating to a number of devices to be managed are collected in an efficient manner. The number of devices 2 to be managed are divided between a direct collection group comprised of some managed devices 2 whose device-condition information are collected by detecting operation by a portable (mobile) unit 4 for device condition detection on each one of these managed devices 2 and an indirect collection group 8a, 8b comprised of the other managed devices 2 whose device-condition information are collected by communication between each one of these managed devices 2 and a stationary unit 5, 6 disposed to be capable of detecting the device-condition information of the device 2.