Raw Sensor Data Control for Low-Complexity Sensor Devices
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Solution Overview
Problem
Existing control systems for complex processes often require significant electronic components on sensor devices for signal processing, leading to security vulnerabilities, configuration difficulties, and inefficient replacements.
Innovation Solution
A system comprising a sensor device with minimal processing electronics and a control system that processes raw sensor data packets, including a sensor identifier, to apply translation functions and models for accurate process variable calculation and control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If significant electronic components are added to sensor devices for signal processing, then measurement precision and control accuracy are improved, but device complexity and security vulnerabilities increase
Solution Approach 1:
The patent extracts the signal processing functionality from the sensor device and relocates it to the control system. The sensor device is reduced to minimal components (sensor element and analog-to-digital converter), while the control system performs translation functions, model applications, and calculations to determine process variable values from raw sensor data.
Solution Approach 2:
The patent introduces raw sensor data packets as an intermediary data format that carries unprocessed sensor readings along with sensor identifiers. This intermediary structure enables the control system to apply translation functions and models to multiple sensor types without requiring complex processing electronics in the sensor devices themselves.
2Measurement precision
If significant electronic components are added to sensor devices for signal processing, then measurement precision is improved, but security vulnerabilities and configuration difficulties increase
Solution Approach 1:
By removing processing electronics from sensor devices, the patent eliminates potential security vulnerabilities and configuration errors that could exist in distributed processing units. The centralized control system provides a single point for secure configuration and processing.
Solution Approach 2:
The sensor device automatically provides raw data and sensor identifiers without requiring local processing or configuration. The control system self-manages the translation functions and models, reducing the need for field configuration and maintenance of sensor device electronics.
3Device complexity
If processing electronics are reduced in sensor devices, then device complexity and cost are reduced, but the control system must handle more processing responsibility
Solution Approach 1:
The patent merges the processing responsibilities of multiple sensor types into a single unified control system architecture. The control system maintains translation functions and models for various sensor types and processes all raw sensor data through a common pathway, improving automation efficiency.
Solution Approach 2:
The control system is designed with universal processing capabilities that can handle multiple sensor types through a single interface. The translation functions and models are configured to work with different sensor identifiers and data formats, allowing one system to perform multiple processing functions.
4Ease of repair
If sensor devices have minimal processing electronics, then ease of replacement and configuration is improved, but raw data processing capability is reduced at the sensor level
Solution Approach 1:
By extracting processing functionality from the sensor device, the patent makes sensor replacement simpler and more reliable. Failed sensors can be replaced without dealing with complex electronics, while the control system continues to provide processing capabilities for all sensors.
Solution Approach 2:
The control system maintains copies of translation functions and models for different sensor types. When a sensor is replaced, the control system uses the sensor identifier to automatically select the appropriate translation function and model, ensuring continuous processing capability without requiring configuration of the replacement sensor.
Data Source
AI summary
Systems, methods, and media for monitoring and controlling an operation (e.g., an automotive manufacturing operation, a chemical processing operation, an oil and gas operation, etc.) using raw sensor data inputs. A system includes a sensor device and a control system in electrical communication with the sensor device. The sensor device includes a sensor configured to generate an electrical signal indicative of a measured process variable and a converter circuit configured to receive the electrical signal and generate a raw sensor data packet using the electrical signal. The control system is configured to receive the raw sensor data packet from the sensor device, calculate a value for the measured process variable based on the raw sensor data packet, and control the operation based on the value for the measured process variable.