Field Sensor Device Redundant Error Reduction
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Solution Overview
Problem
Field sensors, particularly in critical applications like automotive systems, face challenges with accuracy due to drift, material defects, and operational faults, leading to inconsistent measurements over time, which existing diagnostic methods struggle to effectively address.
Innovation Solution
A field-sensor device comprising two field sensors oriented differently to produce signals in distinct orientations, with a controller converting and comparing these signals to detect faults, calculate error signals, and adjust responses to reduce errors, ensuring continued operation even if one sensor fails.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a single field sensor is used, then the device complexity is low, but the measurement precision and reliability deteriorate due to drift and faults
Solution Approach 1:
The system divides the measurement function into multiple independent sensors (first field sensor and second field sensor) oriented at different orientations. Each sensor provides redundant measurement capability, allowing the system to detect and correct individual sensor failures and drift, thereby improving measurement precision without requiring a completely different approach
Solution Approach 2:
The system changes the orientation parameter of sensors relative to each other (first orientation vs. second orientation). This parameter change enables the sensors to measure the same physical quantity from different perspectives, allowing for cross-validation and error detection while maintaining manageable device complexity
2Reliability
If multiple field sensors are used, then the reliability improves through redundancy, but the device complexity increases
Solution Approach 1:
The measurement function is segmented across multiple sensors with different orientations, where each sensor independently contributes to the overall measurement. This segmentation provides reliability through redundancy while keeping each sensor unit simple and manageable
Solution Approach 2:
The system implements feedback by comparing measurements from sensors at different orientations. The controller analyzes discrepancies between sensor readings and uses this feedback to detect faults, identify drifting sensors, and correct measurements, thereby improving reliability while managing the complexity of having multiple sensors
3Measurement precision
If sensors are calibrated, then the measurement precision improves, but the ease of operation deteriorates due to calibration requirements
Solution Approach 1:
The system performs preliminary calibration during manufacturing or initial setup, establishing baseline relationships between sensors at different orientations. This preliminary action captures calibration data that compensates for manufacturing variations and orientation differences, improving measurement precision while eliminating the need for frequent user calibration
Solution Approach 2:
The system implements self-calibration or self-diagnosis capabilities where the controller automatically monitors sensor performance, detects drift, and applies corrections using the redundant sensor measurements. This self-service approach maintains measurement precision without requiring external calibration operations, improving ease of operation
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
The solution enhances diagnostic capabilities, reduces measurement errors, and maintains sensor accuracy by identifying faulty sensors and adjusting responses, thereby providing consistent and accurate field measurements.
Implementation Method 1
Magnetic sensors can incorporate Hall-effect sensors that generate an output voltage proportional to an applied magnetic field
Implementation Method 2
magneto-resistive materials whose electrical resistance changes in response to an external magnetic field
Implementation Method 3
Magnetic sensors can incorporate Hall-effect sensors that generate an output voltage proportional to an applied magnetic field
Implementation Method 4
magneto-resistive materials whose electrical resistance changes in response to an external magnetic field
Data Source
AI summary
A field-sensor device comprises a first field sensor with a first sensor response to a field. The first sensor response is measured in a first orientation to produce a first sensor signal, a second field sensor with a second sensor response to the field the second sensor response measured in a second orientation different from the first orientation to produce a second sensor signal, and a controller for controlling the first and second field sensors to produce respective first and second sensor signals. The controller comprises a control circuit that converts any combination of first and second sensor signals to equivalent first and second comparable sensor signals in a common orientation, calculates an error signal derived from differences between the first and second comparable sensor signals, and adjusts any combination of the first and second sensor responses to reduce the error signal.