Input Channel Alternate Routing for Industrial Sensor Monitoring
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Solution Overview
Problem
Industrial environments face challenges in effectively collecting and utilizing data from multiple sensors due to limited data range, complexity, and variability in network connectivity, leading to inefficient monitoring and optimization of operations.
Innovation Solution
The implementation of methods and systems for continuous ultrasonic monitoring, on-device sensor fusion, self-organizing data marketplaces, and AI training based on industry-specific feedback, along with augmented reality and virtual reality interfaces, to enhance data collection, processing, and utilization in industrial IoT environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If data is collected from multiple sensors in industrial environments, then the quantity and variety of data increases, but the complexity of dealing with data from multiple sensors increases
Solution Approach 1:
The patent segments the data collection system into multiple independent data collectors, each responsible for specific sensors or sensor groups. This segmentation allows parallel processing of data from different sources, reducing the overall complexity of handling multi-sensor data while increasing the quantity of collected data.
Solution Approach 2:
The patent implements universal data collection architectures where data collectors can handle multiple sensor types and protocols through standardized interfaces. This multi-functionality allows the same data collection infrastructure to process diverse sensor data without proportionally increasing system complexity.
2Adaptability or versatility
If data collection infrastructure is upgraded to handle more sensors, then the data range and capability improve, but the capital costs and risks of upgrading equipment increase
Solution Approach 1:
The patent employs universal data collectors with standardized protocols and interfaces that can accommodate multiple sensor types without requiring custom hardware for each sensor. This approach improves sensor compatibility while avoiding the high capital costs associated with dedicated upgrade infrastructure.
Solution Approach 2:
The system implements dynamic sensor assignment where data collectors can be assigned to different sensors or sensor groups based on operational needs rather than fixed hardware assignments. This dynamic allocation allows the system to adapt to changing requirements without physical infrastructure upgrades.
3Device complexity
If all input channels are routed through a single data collector, then the system structure is simple, but the data collector may become overwhelmed and network connectivity variability affects performance
Solution Approach 1:
The patent divides the data collection function across multiple data collectors, each handling specific input channels or sensor groups. This segmentation prevents any single collector from becoming overwhelmed and improves reliability by distributing the data collection load, while maintaining relatively simple individual collector structures.
Solution Approach 2:
The patent introduces a hierarchical dimension to the routing structure, where data collectors operate at different levels (local collectors for specific sensors, central collectors for aggregation). This multi-level architecture improves reliability by creating redundant pathways while keeping individual routing structures simple.
Data Source
AI summary
The present disclosure describes monitoring systems and methods for data collection in an industrial environment. A system can include a data collector and a data acquisition circuit to interpret a plurality of detection values corresponding to input channels, wherein the data acquisition circuit acquires sensor data from a first route of input channels. A data storage stores sensor specifications for sensors and a data analysis circuit evaluates the sensor data with respect to the stored anticipated state information including an alarm threshold level. The data analysis circuit sets an alarm state when the alarm threshold level is exceeded for a first input channel and transmits the alarm state to a routing control facility. A response circuit changes the routing of the input channels to an alternate routing upon reception of a routing change indication from the routing control facility.