Modular Sensor Interface for Low-Cost Expandable Instrumentation
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Solution Overview
Problem
High-tier process instrumentation devices are costly and not suitable for widespread sensor networks, necessitating a low-cost solution with additional features or functions that can be added as needed.
Innovation Solution
A modular sensor device with a universal interface that allows for interchangeable option modules to provide additional functionalities, combining a sensor module, communication module, and a flexible digital and analog interface for cost-effective expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-tier feature-rich field devices are used to monitor process parameters and control actuators, then performance and capabilities are improved, but cost increases significantly making them unsuitable for widespread sensor networks
Solution Approach 1:
The field device is divided into a base unit and separate option modules. The base unit provides core sensing and communication capabilities at low cost, while option modules provide additional specialized functions. This segmentation allows customers to purchase only the base unit for basic needs and add option modules only when additional capabilities are required, significantly reducing overall system cost while maintaining performance where needed.
Solution Approach 2:
The base unit is designed with a universal interface that can accommodate multiple types of option modules through standardized connection mechanisms. This universal design allows a single base unit to support various sensing functions, communication protocols, and control capabilities by simply changing the option module, providing multi-functionality without requiring multiple different base device types.
2Adaptability or versatility
If feature-rich field devices are deployed throughout a sensor network, then comprehensive functionality is achieved, but the overall system cost becomes prohibitively high
Solution Approach 1:
By segmenting the device into base and option components, the system achieves comprehensive functionality through combination rather than through a single expensive all-features device. Each option module can be selected based on specific application requirements, allowing the system to adapt to different functional needs while keeping individual component costs low.
Solution Approach 2:
The system configuration is made dynamic and flexible, allowing customers to customize their sensor network by combining different base units with different option modules based on specific application requirements. This dynamic configurability enables the system to adapt to varying functional needs without locking customers into expensive standardized high-tier devices.
3Adaptability or versatility
If additional features or functions are added to sensor devices, then capability is enhanced, but device complexity and cost increase
Solution Approach 1:
Additional functions are implemented as separate option modules that can be attached to the base unit, rather than being integrated into the base unit design. This keeps the base unit simple and maintains low complexity while allowing functionality to be added modularly. Each option module is an independent unit with its own specific capabilities, making the addition of features straightforward and not complexity-inducing for the base design.
Solution Approach 2:
A universal interface acts as an intermediary between the base unit and option modules, providing standardized connection and communication protocols. This intermediary layer simplifies the integration of additional functions by handling the complexity of interface compatibility and data communication, allowing option modules to be added without increasing the complexity of the base unit or the integration process.
Data Source
AI summary
A sensor device includes a sensor module housing, a sensor module, a communication module, and a universal interface. The sensor module housing is configured to contain the sensor module. The sensor module disposed in the sensor module housing. A communication module is operably coupled to the sensor module. The universal interface configured to couple to an option module to provide an additional function. An extended sensor system is also provided.