Integrated PLC Measuring Device for Automated Industrial Machinery Analysis
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Solution Overview
Problem
Current measuring devices for industrial machines require manual steps to record and evaluate correlations between machine-relevant physical variables, necessitating separate control of each device and compilation of individual measured values for computer program evaluation, which is inefficient and time-consuming.
Innovation Solution
A measuring device with a programmable logic controller (PLC) and multiple measuring modules that can simultaneously measure and record physical variables, transmitting data via a fieldbus communication system for automated analysis, utilizing an OPC server for communication with external devices, and a software program for data analysis and visualization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple measuring devices are used to measure different physical variables, then measurement capability is improved, but device complexity and manual operation requirements increase
Solution Approach 1:
The patent combines multiple measuring modules (power meter, energy meter, flow meter, pressure meter) into a single integrated measuring device with a common control unit and communication interface. This merging approach maintains the ability to measure multiple physical variables while reducing the number of separate devices needed, thereby decreasing system complexity and manual operation requirements.
Solution Approach 2:
The measuring device incorporates multiple measuring modules that can simultaneously measure different physical variables (electrical power, energy, volume flow, pressure) through a single device. The control unit can selectively activate different modules based on measurement requirements, providing universal measurement capability without requiring separate dedicated devices for each variable.
2Measurement precision
If manual recording and compilation of measured values is performed, then data accuracy is maintained, but time consumption and productivity decrease
Solution Approach 1:
The control unit automatically receives measured values from all measuring modules and transmits them via fieldbus communication to an external evaluation device. This automated feedback loop eliminates manual recording steps while maintaining data accuracy through direct digital transmission, significantly improving productivity in data collection and processing.
Solution Approach 2:
The patent replaces the manual mechanical process of recording and compiling measured values with an automated electronic system. The control unit automatically collects data from measuring modules, formats it, and transmits it through fieldbus communication to external evaluation devices, substituting manual operations with automated electronic data handling.
3Reliability
If separate control of each measuring device is required, then individual device reliability is maintained, but ease of operation decreases
Solution Approach 1:
Multiple measuring modules are merged under a single control unit that manages all measurements and data transmission centrally. This unified control architecture simplifies operation by providing a single point of control while maintaining the reliability of individual measuring modules through their dedicated measurement functions and independent data pathways.
Data Source
AI summary
The measuring device (1) has a measuring module (10), which is equipped to measure a physical variable, particularly electric power, and an analog input, which is equipped to receive data (22). A programmable logic controller (20) is equipped to collect the data measured by the measuring module and to collect the data received through the analog input at the same time. The measuring device has a Universal serial bus connection (14). A sensor (12) is connected to the analog input to measure another physical variable. Independent claims are included for the following: (1) an analysis system with a processing unit; and (2) a method for measurement and analysis of industrial machines or -systems.