Modular Sensor System for Industrial Machine Retrofitting
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Solution Overview
Problem
Existing industrial machines require significant modifications and disassembly for retrofitting with autonomous operation systems, leading to increased time and costs, especially when integrating modular sensor systems.
Innovation Solution
A modular sensor system designed to be easily coupled with existing industrial machines, featuring adjustable railings and compartments that can be attached without major modifications, allowing for flexible sensor placement and communication with industrial machine systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If sensors are integrated directly into the industrial machine body, then automation capability is improved, but manufacturing complexity and modification time increase significantly
Solution Approach 1:
The sensor system is divided into separate modular components (sensors, railings, compartments) that can be independently manufactured and then assembled onto the industrial machine. This segmentation allows the sensor system to be developed and tested separately from the machine itself, reducing overall manufacturing complexity while maintaining full automation capability.
Solution Approach 2:
A modular carrier system with railings and compartments acts as an intermediary between the industrial machine body and the sensor components. This intermediary structure provides a standardized interface that simplifies integration, allowing sensors to be mounted without directly modifying the machine body, thereby reducing manufacturing complexity.
2Extent of automation
If industrial machines are disassembled for retrofitting with autonomous systems, then automation integration is improved, but production downtime and costs increase
Solution Approach 1:
The modular sensor system is pre-assembled on standardized railings and compartments before being installed on the industrial machine. This preliminary assembly allows the complete sensor package to be tested and calibrated independently, enabling rapid installation on the machine without requiring disassembly of existing machine components, thereby minimizing production downtime.
Solution Approach 2:
The modular carrier system incorporates adjustable and reconfigurable components that can be dynamically assembled and disassembled. This dynamic design allows the sensor system to be installed or removed without permanent modifications to the machine, enabling quick retrofitting and reducing the time the machine is out of service.
3Ease of operation
If modular sensor systems are designed for easy attachment, then ease of installation is improved, but structural strength and stability may be compromised
Solution Approach 1:
The attachment system is segmented into standardized mechanical interfaces (railings, brackets, mounting points) that provide discrete, pre-engineered attachment locations. These segmented attachment points concentrate loading at specific reinforced locations on the machine body, maintaining structural strength while allowing easy assembly through standardized connection mechanisms.
Solution Approach 2:
The modular carrier system uses universal attachment features that can be configured for different loading requirements and sensor arrangements. The same standardized railing and bracket system can accommodate various sensor weights and configurations while maintaining adequate structural strength through proper mechanical design and material selection.
Data Source
AI summary
A modular sensor system may include railings that connectively couple with one another. The modular sensor system may include a first compartment body that couples to the railings. The modular sensor system may include sensors positioned in an interior region or on an exterior surface of the first compartment body. In some embodiments, the railings may be connectively coupled to define an interior space that includes a shape corresponding to at least a partial perimeter shape of an industrial machine with the interior space of the modular sensor system interfacing with the industrial machine. In some embodiments, a second compartment body may be coupled to the railings. In some embodiments, the modular sensor system may include a surface panel that pivots along an axis of rotation from a first position perpendicular to the railings to a second position parallel to the railings and covering the interior space.