Modular Sensor Hub Architecture for Scalable Industrial Data Collection
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Solution Overview
Problem
Existing industrial data collection systems lack versatility, requiring dedicated hardware for each sensor type, involve complex integration and setup, are not easily scalable, and fail to adapt to different applications or environments.
Innovation Solution
A versatile data collection system with a hub and sensor node architecture that integrates various sensors through a mesh network, utilizing interchangeable microcontrollers to simplify setup and scaling, and supports remote control and data management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If dedicated hardware is used for each sensor type, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent implements a universal data collection hub that can interface with multiple sensor types through a single standardized platform. The hub uses programmable microcontrollers that can be configured to work with different sensor protocols (I2C, SPI, UART, etc.), eliminating the need for dedicated hardware for each sensor type while maintaining measurement precision through software-configurable data acquisition.
2Measurement precision
If specialized instruments are used for data collection, then measurement precision is improved, but ease of operation deteriorates
Solution Approach 1:
The patent implements automatic device identification and configuration where the hub autonomously detects connected sensors, identifies their protocols, and configures data collection parameters without manual intervention. The system performs self-testing, automatic calibration, and generates configuration files automatically, eliminating the need for users to manually configure complex hardware settings while maintaining precise data collection.
3Reliability
If traditional data collection systems are used, then reliability is maintained, but adaptability deteriorates
Solution Approach 1:
The patent implements a dynamic system where the hub can adapt its communication protocols and data collection methods based on the connected sensors. The programmable microcontrollers can be reconfigured through software to support new sensor types without hardware changes, allowing the system to evolve and adapt to changing industrial requirements while maintaining reliable data collection through robust error handling and validation mechanisms.
4Measurement precision
If specialized instruments are used, then measurement precision is improved, but scalability deteriorates
Solution Approach 1:
The patent divides the data collection system into modular components: a central hub, interchangeable sensor nodes, and a software platform. This segmentation allows the system to be scaled by simply adding more sensor nodes to the hub without requiring redesign of the entire system. Each sensor node operates independently as a self-contained unit, enabling linear scalability while maintaining precise measurement through standardized interfaces.
Data Source
AI summary
The invention provides a wireless and modular data collection system for industrial applications. It includes a hub with dual microcontrollers: one managing a mesh network for communication with sensor nodes, and another handling data caching and transmission to a network-accessible server. Sensor nodes are modular and interchangeable, each with a microcontroller that formats data from various sensors for mesh network transmission. The system enables real-time data monitoring via a web-based interface and supports automatic authentication and connection of sensor nodes. This design enhances data collection efficiency, simplifies integration, and scales easily with new sensors, addressing limitations of traditional methods.