Industrial Process Gateway for Wireless Monitoring and Feedback Control

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Solution Overview

Problem

Existing industrial process monitoring systems lack wireless sensor capabilities, intermediate data storage, and efficient data transmission and control signal communication, limiting their ability to handle large data sets and respond to process changes effectively.

Innovation Solution

A method and device that utilize wireless sensor data transmission to a gateway for intermediate processing and storage, followed by cellular data transmission to a remote storage for analysis, enabling control signals to be sent back to the process, with features like 900 MHz RF communication, GPS, Bluetooth, and RS485 standardization for robust and autonomous operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If sensor data is transmitted wirelessly to a remote data repository, then data transmission capability is improved, but data storage capacity and intermediate processing capability deteriorate

Engineering Contradiction:

Improvedata transmission speedVSAvoiddata storage capacity

Core Design Contradiction:

SpeedVSQuantity of substance

Solution Approach 1:

The gateway serves as an intermediary device between sensors and the remote data repository. It receives sensor data via wireless transmission, performs intermediate storage and processing locally, then transmits processed data to the remote repository. This mediator approach resolves the contradiction by providing both wireless transmission capability and local data storage/processing capacity.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system is segmented into distinct functional components: sensors for data collection, gateway for intermediate storage and processing, and remote data repository for long-term storage. This segmentation allows each component to specialize in specific functions, with the gateway handling both wireless reception and local data management, thus resolving the capacity-transmission contradiction.

Inventive Principle:

Principle #1Segmentation

2Productivity

If a centralized data repository is used for storing large data sets, then data analysis capability is improved, but system complexity and communication requirements worsen

Engineering Contradiction:

Improvedata analysis capabilityVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system divides data processing into two stages: preliminary processing at the gateway level (filtering, aggregation) and advanced analysis at the remote repository level. This segmentation reduces the complexity burden on any single component while maintaining overall analytical capability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The gateway performs preliminary data processing and filtering before transmitting data to the remote repository. This preliminary action reduces the volume and complexity of data requiring centralized analysis, making the overall system more manageable while preserving analytical capabilities.

Inventive Principle:

Principle #10Preliminary action

3Extent of automation

If control signals are transmitted back to the process, then process control capability is improved, but communication infrastructure requirements worsen

Engineering Contradiction:

Improveprocess control capabilityVSAvoidcommunication infrastructure

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The system implements a feedback loop where the gateway receives control commands from the remote system and transmits them to process control devices. This feedback mechanism enables automated process control while utilizing the existing wireless communication infrastructure, avoiding the need for separate dedicated control communication channels.

Inventive Principle:

Principle #23Feedback

4Measurement precision

If multiple sensors are deployed to monitor process conditions, then measurement precision is improved, but data management complexity and power requirements worsen

Engineering Contradiction:

Improveprocess monitoring precisionVSAvoidpower consumption

Core Design Contradiction:

Measurement precisionVSUse of energy by moving object

Solution Approach 1:

Multiple sensor data streams are merged and aggregated at the gateway rather than being managed independently. The gateway consolidates data from multiple sensors, performs collective processing, and manages power efficiently by controlling when and how data is transmitted wirelessly, thus reducing overall power consumption while maintaining monitoring precision.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS11460816B2Method for monitoring and controlling an industrial process which change condition over time and a communication gateway

Publication Date: 2022.10.04 AMI GLOBAL

AI summary

A method for monitoring and controlling an industrial process which changes condition over time includes collecting sensor data from a sensor affected by the industrial process and transmitting it to a gateway for processing, transmitting processed sensor data using a cellular device from the gateway to a remote data storage for further processing, sending instructions back to the gateway using the cellular device, producing control signals at the gateway based on the instructions, and sending the control signals to a control device connected to the industrial process.