Modular Measurement Device With Swappable Sensor Units

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Solution Overview

Problem

Existing mobile hand-held measuring devices often fail completely if a functional unit, such as a sensor or interface, malfunctions, requiring the entire device to be sent for repair or calibration, leading to downtime and inefficiency.

Innovation Solution

A modular system comprising separate sensor units for different physical or chemical variables and communication units with various interfaces, allowing for flexible assembly and easy replacement of defective units, reducing downtime and maintenance efforts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a functional unit (sensor or interface) malfunctions in a handheld measuring device, then the entire device fails and must be sent for repair, but this causes complete downtime and loss of productivity

Engineering Contradiction:

Improvedevice reliabilityVSAvoidmeasurement productivity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The measuring device is divided into separate functional modules (sensor unit, communication unit, evaluation unit) that can be independently replaced. This segmentation allows only the defective module to be sent for repair while other modules remain operational, preventing complete device failure and maintaining productivity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent implements a module replacement strategy where defective sensor or communication units are quickly swapped out and sent for repair, while the repaired modules are recovered and reused in the field device. This extends the service life of individual components and maintains overall system availability.

Inventive Principle:

Principle #34Discarding and recovering

2Measurement precision

If the entire device is sent away for sensor calibration, then measurement accuracy is maintained, but measurements are only possible with a replacement device during this time

Engineering Contradiction:

Improvesensor calibration accuracyVSAvoidcalibration downtime

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

By separating the sensor unit from the main device housing, the patent enables independent calibration and replacement of sensor modules. This allows rapid swapping of calibrated sensor units in the field, minimizing calibration downtime while maintaining measurement precision through proper calibration of individual sensor modules.

Inventive Principle:

Principle #1Segmentation

3Adaptability or versatility

If a modular system with multiple sensor units and communication units is implemented, then flexibility and adaptability are improved, but device complexity increases

Engineering Contradiction:

Improvemeasuring device flexibilityVSAvoidsystem complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent implements universal mechanical coupling interfaces and standardized electrical connections that work across different sensor and communication units. This universality allows multiple specialized modules to be integrated into a coherent system without proportionally increasing complexity, as the same interface standards apply to all module combinations.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system is segmented into standardized modules with defined interfaces, which actually reduces overall complexity compared to integrated designs. Each module can be independently developed, tested, and maintained, simplifying the management of system complexity while enabling high adaptability through modular reconfiguration.

Inventive Principle:

Principle #1Segmentation

4Ease of repair

If separate modular units are used instead of an integrated device, then repair and maintenance become easier, but the number of parts and assembly requirements increase

Engineering Contradiction:

Improvesensor replacement easeVSAvoidnumber of parts

Core Design Contradiction:

Ease of repairVSDevice complexity

Solution Approach 1:

The patent divides the measuring device into distinct sensor units, communication units, and evaluation units that can be independently accessed and replaced. This segmentation dramatically simplifies repair operations, as technicians can replace individual sensor modules without disassembling the entire device, despite the increased number of separate parts.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

While the system uses separate modular units, the mechanical coupling and electrical connection systems merge these units into a functionally integrated assembly during operation. This merging approach allows easy separation for repair while maintaining a unified, manageable structure during normal use, effectively hiding the complexity of multiple parts.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentEP3529565B1Construction kit for construction of a measurement device

Publication Date: 2021.12.08 TESTO SE & CO KGAA

Figure 1(a)~1(g)
Figure 2(a)~5
Figure 6(a)~8

AI summary

The invention relates to a measurement device (13) which can be assembled from a construction kit, wherein the construction kit comprises at least two sensor units (1) which are designed to measure in each case different variables, and at least two communication units (6) which have in each case different interfaces for transmitting data, each of the sensor units (1) being detachably connectable to each of the communication units (6) of the construction kit via a mechanical coupling (7).