Power Cord Field Sensing for Noninvasive Machine Usage Tracking
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Solution Overview
Problem
Existing methods for determining the usage metrics of machines, such as centrifuges, are invasive, costly, and can void warranties, while also introducing liability and safety issues due to the need for direct current measurement and potential interference with the machine's operation.
Innovation Solution
A non-invasive electromagnetic apparatus (EMA) that measures electromagnetic fields generated by the current flowing through a power cord, allowing for the estimation of power consumption and usage metrics without direct contact with the machine's conductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If direct current measurement methods (smart plugs, split core transformers) are used to determine machine usage metrics, then measurement capability is improved, but safety and liability issues worsen due to invasive connection requirements
Solution Approach 1:
The patent introduces an electromagnetic field as an intermediary carrier to transfer information about current consumption. Instead of directly measuring current through invasive electrical connections, the system measures the electromagnetic field generated by the current flow in the power cord, which serves as a safe mediator that carries the same information without requiring direct electrical contact.
Solution Approach 2:
The patent replaces the mechanical/electrical measurement system (smart plugs, split core transformers that require physical insertion and electrical contact) with an electromagnetic field sensing system. This substitution eliminates the need for invasive electrical connections while maintaining the ability to measure current-related parameters through non-contact electromagnetic field detection.
2Loss of information
If smart plugs are used to measure current, then usage data collection is improved, but warranty validity worsens as manufacturers may void warranties when machines are plugged through third-party devices
Solution Approach 1:
The electromagnetic field acts as an intermediary that allows usage data collection without the machine being directly connected to the measurement device. The power cord remains directly plugged into the wall outlet, maintaining the manufacturer-recommended connection, while the electromagnetic field measurement occurs separately through the power cord's external electromagnetic emissions.
Solution Approach 2:
The system creates a copy of the current information through electromagnetic field measurement rather than measuring the current directly. The electromagnetic field contains a copy of the electrical signal characteristics, allowing usage metrics to be derived from this field copy without interrupting or modifying the original electrical connection between the machine and power source.
3Ease of manufacture
If consumer-grade smart plugs are used for current measurement, then cost is reduced, but measurement reliability worsens due to lower manufacturing tolerances compared to expensive machines
Solution Approach 1:
The electromagnetic field serves as an intermediary that decouples the measurement system from the electrical connection requirements. This allows the use of electromagnetic sensing technology rather than precision electrical measurement components, potentially enabling more cost-effective sensor solutions while maintaining measurement capability through the field-based approach.
4Extent of automation
If RF transmitters are placed in smart plugs near machine conductors, then communication capability is improved, but line noise interference worsens affecting sensitive machine operation
Solution Approach 1:
The patent extracts the RF transmitter from the measurement system entirely, eliminating the source of potential interference. Instead of embedding an RF transmitter in a smart plug near the machine's electrical conductors, the system uses electromagnetic field sensing for measurement and relies on other communication methods that do not require placing transmitting electronics in close proximity to sensitive electrical components.
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
The EMA provides a reliable and cost-effective means to monitor machine usage without invasive measurements, reducing liability and ensuring machine safety, while allowing for accurate estimation of power consumption and operational parameters.
Implementation Method 1
measures electromagnetic fields generated by the current flowing through a power cord
Data Source
AI summary
An electromagnetic apparatus (EMA) for measuring electromagnetic properties of an electrical conductor such as a power cord is provided. Methods of using the EMA are also provided. The EMA includes a plurality of electromagnetic sensors (EMSs) disposed in an array along a length and a width of the EMA. The EMA further includes circuitry such as a microprocessor, communication circuitry, and power circuitry. The circuitry is in electrical communication with the EMSs.