Optical Gauge Digitization for Non-Intrusive Machine Telemetry
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Solution Overview
Problem
Existing machine-to-machine (M2M) communication systems face challenges in converting analog machine telemetry and signals into digital form for transmission over the internet without interfering with the machine's operation or requiring extensive modifications, especially in regulated or safety-critical environments.
Innovation Solution
A system that uses a camera to capture images of machine gauges and indicators, digitizing them without physical or electrical connection to the machine, employing image processing and optical character recognition to extract digital values, which are then transmitted over a network, eliminating the need for reconfiguration or additional digitizing equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If analog telemetry and signals from a machine are converted into digital form using traditional digitizing equipment, then digital transmission over the internet is enabled, but extensive modifications to the machine and interruption of the electrical signaling systems are required
Solution Approach 1:
The patent uses a camera to capture optical images of analog gauges and indicators, creating a digital copy of the visual information without physically or electrically connecting to the machine. This optical copying approach enables digital transmission while avoiding modifications to the machine's electrical signaling systems
Solution Approach 2:
The patent replaces traditional electrical/mechanical digitizing equipment with an optical system (camera). Instead of using electrical connections to read gauge values, the system uses optical imaging to capture and digitize the visual display, thereby substituting a mechanical/optical approach for electrical approaches
2Extent of automation
If new circuitry is added to digitize analog gauges or tap into existing digital signals, then digital communication is enabled, but warranty violations and safety issues occur
Solution Approach 1:
The patent introduces a camera as an intermediary device that captures optical information from the gauge without directly connecting to the machine's electrical or digital systems. This intermediary approach enables digital communication while maintaining isolation from the machine's protected systems, thereby preserving warranty and safety compliance
3Reliability
If high voltage circuits are isolated from low voltage digitizing circuits, then safety is improved, but additional isolation equipment and complexity are required
Solution Approach 1:
The patent replaces electrical isolation requirements with an optical isolation approach. By using a camera to capture optical images of the gauges, the system achieves safety isolation without needing electrical isolation equipment, as the optical path naturally prevents electrical interference and high voltage contact
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the digitization of machine gauges and indicators without disrupting the machine's operation, allowing for remote monitoring and communication of machine status without interfering with existing wiring or signaling systems, and provides additional security and information capture beyond traditional digital telemetry.
Implementation Method 1
A camera images a field of view and provides an image frame that is comprised of an image area
Data Source
AI summary
A system for digitizing gauges, lights and other human-readable machine gauges and functions and status without interfering with the operation of the machine or requiring re-working or interfering with the existing machine wiring, signaling, electrical or mechanical elements or operating modes, or adding new digitizing equipment to the machine.