Industrial Equipment Tagging for Data Consistency
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Solution Overview
Problem
In industrial systems, the replacement of defective equipment often leads to inconsistent data representation, resulting in poor system performance and costly efforts to correct data quality issues due to the detachment of the information update process from the physical replacement process.
Innovation Solution
A method and system for monitoring the operating conditions of industrial equipment using sensors and electrically identifiable tags, where a microprocessor-based management system determines defective devices, identifies replacement devices, and updates location information in memory to ensure accurate data representation, closely linking equipment replacement with information model updates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If equipment replacement is performed manually with separate information update processes, then equipment can be replaced, but data consistency and quality deteriorate due to detachment between physical replacement and information updates
Solution Approach 1:
The patent merges the physical equipment replacement process with the information update process into a single integrated operation. When equipment is physically replaced, the system automatically updates the information model to reflect the new equipment's identity, location, and status, eliminating the detachment between physical and informational changes that previously caused data inconsistency.
Solution Approach 2:
The system enables self-service by automatically updating equipment information records without requiring manual intervention. The information model self-corrects and self-updates when equipment replacement occurs, using automated detection and data synchronization mechanisms to maintain consistency between physical equipment status and digital records.
2Productivity
If manual tracking of equipment location and identity is used, then equipment replacement can be performed, but time consumption increases and error rates rise
Solution Approach 1:
The patent replaces manual mechanical tracking methods with automated electronic identification and data management systems. Barcode scanners, RFID readers, or other automated detection devices capture equipment identity and location information, which is then automatically processed and updated in the information model, eliminating time-consuming manual data entry and reducing human error.
Solution Approach 2:
The system performs preliminary actions by pre-configuring equipment information records with unique identifiers and location data before replacement occurs. This allows the system to automatically match and update records during replacement without requiring time-consuming manual search and verification, thereby improving replacement efficiency and reducing time loss.
3Reliability
If comprehensive equipment monitoring is implemented, then system reliability improves, but system complexity increases due to additional sensors and data management requirements
Solution Approach 1:
The patent implements multi-functional monitoring components that perform multiple tasks simultaneously. Sensors not only monitor equipment operating conditions but also serve as identification and location tracking devices. The information model serves both as a data storage repository and as an active management system that automatically triggers replacement workflows, reducing overall system complexity through functional consolidation.
Data Source
AI summary
A system and method for monitoring operating conditions of an industrial installation system including a plurality of pieces of equipment. Each of the pieces of equipment includes a sensor and an electrically identifiable tag configured to identify the equipment. The sensors of each of the plurality of pieces of equipment provide an operating characteristic of the piece of equipment that is provided to an industrial equipment management system. The system is also configured to store the content of the electrically identifiable tag and to store a location identifier of each of plurality of pieces of equipment. Replacement of the identified defective equipment is made with replacement equipment having an identifier that uniquely identifies the replacement device and the location of the replacement device in the industrial installation system.