Modular Sensor Unit Layout for Flexible Placement and Replacement
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Solution Overview
Problem
Sensors face challenges in achieving small form factors and ideal placement due to the need for additional components to measure, amplify, convert, and transmit signals, and they often have limited lifespans requiring frequent replacement.
Innovation Solution
A modular sensor system with a sensor module and a component module connected via a power cable ribbon, allowing for modular design, flexibility in placement, and easy replacement of components, with integrated signal processing and edge computing to reduce burden on the sensor unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If additional components are added to measure, amplify, convert, and transmit sensor signals, then measurement and processing capability is improved, but sensor form factor increases and placement flexibility decreases
Solution Approach 1:
The sensor system is divided into separate functional modules: a sensor module containing only the sensing element and a component module containing signal processing components. These modules are connected via a flexible printed circuit board (FPC), allowing the sensor itself to remain small while processing capabilities are distributed to the separate component module.
Solution Approach 2:
A flexible printed circuit board (FPC) is introduced as an intermediary connection between the sensor module and component module. This FPC carries both power and signal transmissions, enabling the separation of sensing and processing functions while maintaining compact overall system design.
2Productivity
If sensor components are integrated into a single unit, then signal processing efficiency is improved, but component replacement frequency increases due to limited sensor lifespan
Solution Approach 1:
The sensor system is segmented into replaceable sensor module and permanent component module. The sensor module with limited lifespan can be independently replaced without replacing the entire system or the expensive component module, reducing maintenance costs and improving ease of repair.
3Ease of repair
If sensor components are separated into modular units, then component replacement ease is improved, but device complexity increases
Solution Approach 1:
The FPC serves as a unified connection medium that combines power transmission, signal transmission, and mechanical mounting functions into a single integrated component. This merging approach simplifies the modular system by reducing the number of separate connections and interfaces needed.
Solution Approach 2:
The FPC performs multiple functions simultaneously: it provides mechanical support for mounting the sensor module, transmits power from the component module to the sensor module, and carries signal transmissions between modules. This multi-functionality reduces overall system complexity despite the modular architecture.
Data Source
AI summary
A method, a computer program product, and a computer system for a modular sensing unit is provided. The method includes mounting a sensor module of the modular sensing unit to a surface. Data of the surface is measured via a sensor component. The data is transmitted from the sensor module to a component module of the modular sensing unit via a power cable ribbon, and a metric is determined by the component module based on the data.