Field Device Diagnostics Using Stereo Acoustic and Thermal Sensing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing diagnostic methods for field devices in automation technology are time-intensive, labor-intensive, and require special expertise, with increased risk of accidents, and lack precision in identifying the spatial location of error sources, especially in passive methods.
Innovation Solution
A diagnostic device comprising a control unit, a sensor carrier with a stereo acoustic sensor, multiple temperature sensors, and optionally magnetic field, photosensor, position sensor, acceleration sensor, GPS sensor, and pressure sensor, allowing for contactless, location-dependent identification of error sources through comparison of reference and operating profiles without interrupting the field device's operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If active diagnostic methods are used to measure electrical characteristics of components, then diagnostic information can be obtained, but the method becomes time-intensive, labor-intensive, and requires special expertise
Solution Approach 1:
The patent replaces active electrical measurement systems with passive acoustic and thermal sensing systems. Instead of injecting electrical signals and measuring electrical characteristics, the system uses microphones to capture acoustic emissions and temperature sensors to detect thermal changes, eliminating the need for electrical safety expertise and reducing diagnostic time while maintaining measurement precision.
Solution Approach 2:
The field device diagnoses itself passively through acoustic and thermal signatures without requiring external active intervention. The diagnostic device merely observes the natural acoustic emissions and temperature variations produced by the field device during operation, enabling continuous monitoring without interrupting operation or requiring manual measurement activities.
2Measurement precision
If active diagnostic methods supply power to the field device, then component characteristics can be measured, but the risk of accidents increases
Solution Approach 1:
The patent substitutes electrical measurement methods with acoustic and thermal measurement methods. By using microphones to detect acoustic emissions and temperature sensors to monitor thermal characteristics, the system eliminates the need to supply power to the field device during diagnosis, thereby removing the associated accident risks while still obtaining precise component characteristic data.
3Object-affected harmful factors
If passive diagnostic methods are used to avoid intervention in the circuit, then safety risks are reduced, but precision in spatial identification of error sources is insufficient
Solution Approach 1:
The patent adds spatial dimensionality to passive acoustic diagnosis by using an array of microphones positioned at different locations. By analyzing the time differences of acoustic signal arrival at each microphone and the amplitude variations across the array, the system can precisely triangulate the spatial location of error sources, transforming a one-dimensional passive detection into a multi-dimensional spatial localization system.
Solution Approach 2:
The patent divides the acoustic sensing function into multiple independent microphones positioned at different spatial locations. Each microphone captures acoustic emissions from a specific direction or region, and the control unit integrates data from all microphones to achieve precise spatial identification of error sources, breaking down the complex task of location identification into manageable directional segments.
4Measurement precision
If active diagnostic methods are used, then component operability can be assessed, but manual intervention and special expertise are required
Solution Approach 1:
The patent replaces complex electrical measurement procedures with simple acoustic and thermal sensing operations. The diagnostic device automatically captures acoustic emissions and temperature data, and the control unit performs all analysis operations, eliminating the need for technicians to have specialized electrical measurement knowledge or to perform manual measurement steps, thereby dramatically improving ease of operation while maintaining assessment precision.
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 precise, contactless diagnosis of field devices without special electrical safety knowledge, providing location-dependent error identification and wear state information, reducing the need for manual intervention and maintaining continuous diagnostic capabilities.
Implementation Method 1
a stereo acoustic sensor (4), which is fastened to the sensor carrier (3)
Implementation Method 2
a first temperature sensor (5), which is fastened on the sensor carrier (3) at a first position, and a second temperature sensor (6), which is fastened on the sensor carrier (3) at a second position
Data Source
AI summary
The present disclosure relates to a diagnostic device for a field device from the field of automation technology, comprising a control unit, a sensor carrier, a stereo acoustic sensor, which is fastened to the sensor carrier, a first temperature sensor, which is fastened at a first position on the sensor carrier, and a second temperature sensor, which is fastened at a second position on the sensor carrier. The first position and the second position are remote from one another owing to a first spacing. The sensor carrier is suitable for being expanded such that the first spacing is changed.