Digital Twin Sensor Configuration for Custom Cable Lengths
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Solution Overview
Problem
Current sensor systems require extensive manual parameterization and customization in industrial plants, leading to inefficiencies and resource waste due to the need for technicians to adjust settings and cable lengths for each device, which is time-consuming and costly.
Innovation Solution
A digital twin sensor system is created, allowing for virtual parameterization and configuration within a construction program, such as SolidWorks or Siemens NX Designer, enabling automatic detection and conversion of settings and cable lengths, and real-time adaptation of sensors to specific plant requirements before production, reducing the need for manual adjustments and minimizing resource waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If sensors are delivered with very long cables to serve multiple uses, then adaptability is improved, but resource waste increases due to cable shortening
Solution Approach 1:
The patent applies preliminary action by determining the exact cable length required during the plant construction planning phase using the digital twin, before the actual sensor is manufactured. This allows cables to be cut to precise lengths during production rather than shortening them later, eliminating waste while maintaining adaptability to different application requirements.
2Adaptability or versatility
If manual parameterization is performed at each device by technicians, then customization to specific requirements is achieved, but time consumption increases significantly
Solution Approach 1:
The patent uses a digital twin as a virtual copy of the physical sensor that can be configured and parameterized during plant construction planning. All parameterization work is performed on the digital twin in advance, eliminating the need for time-consuming manual parameterization at each physical device during installation and commissioning.
Solution Approach 2:
The patent performs all sensor parameterization, configuration, and adaptation work during the plant construction planning phase using the digital twin, before the actual sensor is installed. This preliminary parameterization eliminates the need for technicians to perform time-consuming adjustments at each device during commissioning.
3Adaptability or versatility
If different cable lengths are made available as standard sensors, then adaptability is improved, but storage costs increase
Solution Approach 1:
The patent changes the approach from providing multiple physical sensor variants with different cable lengths to providing a single sensor platform where the cable length is determined by digital parameters during planning. The digital twin stores the required cable length information, and the actual cable length is produced according to these parameters, eliminating the need to manufacture and store multiple sensor variants.
4Adaptability or versatility
If extensive manual parameterization and customization is performed, then sensor adaptation to specific requirements is achieved, but productivity decreases due to time-consuming processes
Solution Approach 1:
The patent uses the digital twin as a virtual replica where all parameterization and customization work can be performed during plant construction planning. This virtual configuration is then transferred to the physical sensor, maintaining full adaptability while dramatically improving productivity by eliminating repetitive manual setup work during commissioning.
Data Source
AI summary
System and method for producing a sensor for a processing machine/plant, wherein a digital twin sensor is provided that is related to the sensor, wherein the digital twin sensor is stored in a database (10), wherein the digital twin sensor forms a data model of the sensor, wherein the data model comprises at least one data building block with data for a sensor housing, for an electronic system, for a control and evaluation unit, for a primary sensor element and/or for mechanical components of the sensor, wherein the digital twin sensor is loaded into a construction program for the processing machine/plant, wherein the digital twin sensor is configured in the construction program, wherein the digital twin sensor is adapted to the processing machine/plant and the adapted digital twin sensor is produced as a real adapted sensor.