Industrial Inspection Handset Power Management
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Solution Overview
Problem
Industrial inspection handsets are limited by the need for a tethered connection to a base unit for power and processing, restricting flexibility and portability, and existing solutions fail to provide sufficient battery life for untethered operations.
Innovation Solution
The integration of a battery assembly with a connector for charging, a battery circuit for communication with the handset processor, and a charge indicator, along with advanced power management methods that adjust power output based on usage patterns and conditions to maximize battery life and reduce power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a battery assembly is integrated into the handset to eliminate the base unit connection, then portability and flexibility are improved, but battery life is insufficient for extended inspection operations
Solution Approach 1:
The power management system dynamically adjusts power output levels based on real-time monitoring of inspection activities. The system transitions between different power states (high power during active inspection, low power during idle periods) to maximize battery life while maintaining operational capability throughout the inspection duration
Solution Approach 2:
The system changes operational parameters such as illumination intensity, processor performance levels, and component power states based on inspection needs and battery charge levels. This allows the handset to adapt power consumption to extend battery life while maintaining sufficient performance for the required inspection duration
2Reliability
If maximum power is provided to all components for extended operation, then operational capability is maintained, but battery life is reduced
Solution Approach 1:
The power management system applies partial power to components based on actual inspection needs rather than maximum power to all components. It selectively activates only the necessary subsystems (illumination, imaging, processing) at appropriate power levels, reducing overall power consumption while maintaining sufficient operational capability for reliable inspection
Solution Approach 2:
The system implements periodic monitoring of battery charge levels and operational patterns, adjusting power distribution in cycles between high-performance modes and power-saving modes. This periodic adjustment maintains operational reliability during active inspection while extending battery life during transitions and idle periods
Data Source
AI summary
An industrial inspection handset is disclosed, comprising a battery assembly for providing power to the handset, wherein the battery assembly comprises a connector for connecting a battery charger, a battery circuit for communicating with a processor in the handset, and a battery charge indicator on the surface of the battery assembly connected to the battery circuit for providing a visual indication of the charge remaining in the battery assembly. A method of power management for an industrial inspection handset is also disclosed comprising the steps of setting a first maximum power output value for the camera illumination for the insertion, monitoring an imager signal processor, to determine that the gain value of the image signal processor is less than a predetermined gain value, and setting a lower second maximum power output value for the camera illumination in order to increase the gain value. Additional methods of power management for an industrial inspection handset are disclosed, comprising the steps of setting a first maximum power output value for the articulation of the insertion tube attached to the handset, monitoring the operator controls to determine that there has been no articulation for a first predetermined amount of time, monitoring the position of the insertion tube to determine whether the insertion tube position is inside or outside of a predetermined zone of coordinates, and reducing or turning off the articulation power to hold the position of the insertion tube.