Industrial IoT Sensor Switching for Real-Time Multi-Sensor Diagnostics
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Solution Overview
Problem
Heavy industrial environments face challenges in data collection and utilization due to the complexity of dealing with data from multiple sensors, limiting the effectiveness of 'smart' solutions for optimization and diagnosis, with existing methods being time-consuming and inefficient.
Innovation Solution
The implementation of a system for continuous ultrasonic monitoring, cloud-based machine pattern recognition, on-device sensor fusion, self-organizing data marketplaces, and AI training based on industry-specific feedback, along with a distributed ledger for tracking transactions, enables efficient data collection, processing, and utilization at the edge and in the cloud.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If data is collected by human beings using dedicated data collectors and recorded on media for later analysis, then data can be collected from multiple sensors, but the process is time-consuming and takes weeks or months to complete analysis
Solution Approach 1:
The patent replaces manual data collection and analysis processes with automated electronic systems. Sensors automatically collect data from industrial equipment and transmit it through a network to a server that performs automated analysis, eliminating the need for human data collectors to manually record data on media and perform time-consuming batch analysis.
Solution Approach 2:
The system enables continuous data collection and analysis operations. Instead of batch processing data weeks or months at a time, the automated system continuously collects sensor data, transmits it in real-time, and performs ongoing analysis, allowing for immediate detection and response to equipment issues.
2Device complexity
If the range of available data is limited in industrial environments, then device complexity is reduced, but the effectiveness of smart solutions for optimization and diagnosis is limited
Solution Approach 1:
The patent creates a universal data collection and analysis platform that can handle multiple types of sensor data from various industrial equipment. The system is designed to accommodate different sensors, communication protocols, and analysis requirements, making it adaptable to diverse industrial applications while maintaining a consistent architecture.
Solution Approach 2:
The network server acts as an intermediary between sensors and analysis tools. It collects data from multiple sensors, standardizes the data format, performs initial processing, and makes data available to various analysis applications, thereby enabling smart solutions without requiring complex direct connections between each sensor and analysis tool.
3Ease of operation
If batches of data are returned to a central office for analysis, then centralized control is maintained, but the process is inefficient and does not enable real-time monitoring and optimization
Solution Approach 1:
The patent segments the data analysis function from centralized batch processing to distributed real-time processing. Multiple servers or computing nodes can independently analyze data streams from different equipment, enabling parallel processing and real-time insights while maintaining centralized coordination through the network architecture.
Solution Approach 2:
The system performs preliminary data processing and analysis at the source before data is fully aggregated centrally. Sensors and edge devices perform initial data filtering, validation, and preliminary analysis, preparing data for more sophisticated centralized analysis, thereby improving overall processing efficiency and reducing the burden on central systems.
Data Source
AI summary
The system generally includes a crosspoint switch in a local data collection system having multiple inputs and multiple outputs including a first input connected to a first sensor and a second input connected to a second sensor. The multiple outputs include a first output and a second output configured to be switchable between a condition in which the first output is configured to switch between delivery of a first sensor signal and a second sensor signal and a condition in which there is simultaneous delivery of the first sensor signal and the second sensor signal. Each of multiple inputs is configured to be individually assigned to any of the multiple outputs. The local data collection system includes multiple data acquisition units each having an onboard card set configured to store calibration information and maintenance history.