Main Sensor Data Forwarding for PLC-Free Process Monitoring

Solution Overview

Problem

The integration of multiple sensors into existing data processing systems for industrial processes is complex and costly due to the need for additional components and programming efforts, particularly with the use of programmable logic controllers (PLCs).

Innovation Solution

A process monitoring system that utilizes a main sensor to acquire and forward measurement data from additional sensors to a data evaluation unit, eliminating the need for a separate PLC by using a dual data link architecture, where the main sensor receives and transmits data from additional sensors via different hardware interfaces, such as S0 pulse interfaces or Ethernet connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a programmable logic controller (PLC) is used to receive and forward measurement data from additional sensors, then data transmission capability is improved, but device complexity and cost increase due to additional components and programming requirements

Engineering Contradiction:

Improvedata transmission capabilityVSAvoidsystem complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The main sensor is designed to perform multiple functions: it not only measures its own process variable but also receives measurement data from additional sensors via a first data link and transmits both its own and the additional sensor's data to the data evaluation unit via a second data link. This multi-functionality eliminates the need for a separate PLC, reducing system complexity while maintaining data transmission capabilities.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The functionality of the main sensor and the PLC is merged into a single device. The main sensor incorporates the data reception and forwarding capabilities that would traditionally require a separate PLC, thereby combining multiple components into one integrated unit and simplifying the overall system architecture.

Inventive Principle:

Principle #5Merging (Combining)

2Adaptability or versatility

If a programmable logic controller (PLC) is used to integrate multiple sensors, then data processing capability is improved, but cost increases due to additional components, energy supply requirements, and programming efforts

Engineering Contradiction:

Improvedata processing capabilityVSAvoidnumber of components

Core Design Contradiction:

Adaptability or versatilityVSQuantity of substance

Solution Approach 1:

The main sensor is designed to perform multiple functions: it not only measures its own process variable but also receives measurement data from additional sensors via a first data link and transmits both its own and the additional sensor's data to the data evaluation unit via a second data link. This multi-functionality eliminates the need for a separate PLC, reducing system complexity while maintaining data transmission capabilities.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The functionality of the main sensor and the PLC is merged into a single device. The main sensor incorporates the data reception and forwarding capabilities that would traditionally require a separate PLC, thereby combining multiple components into one integrated unit and simplifying the overall system architecture.

Inventive Principle:

Principle #5Merging (Combining)

3Quantity of substance

If multiple separate sensors are integrated into the data processing system, then measurement coverage is improved, but ease of operation deteriorates due to complex integration and maintenance requirements

Engineering Contradiction:

Improvenumber of sensorsVSAvoidintegration simplicity

Core Design Contradiction:

Quantity of substanceVSEase of operation

Solution Approach 1:

The main sensor acts as an intermediary between the additional sensors and the data evaluation unit. It receives data from the additional sensors via the first data link, processes and converts the data if necessary, and forwards all measurement data to the data evaluation unit via the second data link. This intermediary role simplifies the integration process and reduces maintenance complexity.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The main sensor is designed to perform multiple functions: it not only measures its own process variable but also receives measurement data from additional sensors via a first data link and transmits both its own and the additional sensor's data to the data evaluation unit via a second data link. This multi-functionality eliminates the need for a separate PLC, reducing system complexity while maintaining data transmission capabilities.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS20240045393A1Process Monitoring System

Publication Date: 2024.02.08 SICK AG

AI summary

The present invention relates to a process monitoring system for monitoring an industrial process, said process monitoring system comprising a main sensor and at least one additional sensor separate from the main sensor, wherein the process monitoring system furthermore comprises a data evaluation unit separate from the sensors, wherein the main sensor and the additional sensor are each configured to acquire measurement data. The main sensor is coupled to the additional sensor via a first data link and is configured to receive the measurement data of the additional sensor via the first data link, wherein the main sensor is coupled to the data evaluation unit via a second data link and is configured to transmit its own measurement data and the measurement data of the additional sensor to the data evaluation unit via the second data link.