Reconfigurable Sensor Controllers for Higher In-Field Resolution
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing sensors have wide sensing ranges and are often not field-configurable, leading to suboptimal sensor resolution and requiring manual reconfiguration, which is often not performed correctly or at all, resulting in inefficiencies and increased inventory and labor costs.
Innovation Solution
Controllers with auto-adjustable in-field reconfigurable sensors that automatically determine and set narrower sensor ranges based on specific system setups, using machine learning and communication protocols like BLUETOOTH and ModBus, enhancing sensor resolution without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If sensors have wide sensing ranges, then they can monitor broader operating conditions, but sensor resolution decreases
Solution Approach 1:
The sensor system dynamically adjusts its sensing range through field reconfiguration capabilities. The controller automatically determines optimal narrower sensor ranges based on specific system setups and operating conditions, allowing the sensor to transition from a fixed wide range to multiple adjustable narrower ranges, thereby resolving the contradiction between wide adaptability and measurement precision
Solution Approach 2:
The invention changes the operational parameters of the sensor by implementing auto-adjustable in-field reconfigurable sensing ranges. The controller modifies sensor configuration parameters automatically to select appropriate narrower ranges for different operating conditions, enabling the sensor to maintain high resolution across various applications while retaining the capability to adapt to different sensing requirements
2Adaptability or versatility
If manual reconfiguration of sensors is required, then sensor ranges can be adjusted, but labor costs and errors increase
Solution Approach 1:
The sensor system performs self-service through automatic reconfiguration. The controller automatically determines the optimal sensor ranges based on system setup and operating conditions without requiring manual intervention. This eliminates labor costs and human errors associated with manual adjustment while maintaining the ability to adapt sensor ranges to specific applications
Solution Approach 2:
The system implements feedback mechanisms where the controller continuously monitors operating conditions and automatically adjusts sensor ranges accordingly. This closed-loop approach ensures optimal sensor configuration is maintained without manual intervention, resolving the contradiction between adaptability and ease of operation
3Adaptability or versatility
If multiple sensor types with different ranges are stocked, then specific applications can be covered, but inventory costs increase
Solution Approach 1:
The invention implements universality by enabling a single sensor type to perform multiple functions through field reconfiguration. The auto-adjustable sensor can be configured to different narrower ranges to cover various applications, eliminating the need to stock multiple specialized sensor types while maintaining comprehensive application coverage
Solution Approach 2:
The sensor system dynamically adapts its sensing range to match different application requirements. Instead of requiring static inventory of multiple sensor types, the reconfigurable sensor changes its operational characteristics in response to different system setups, reducing inventory variety while maintaining versatility
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Exemplary embodiments are disclosed of controllers (e.g., control panels, etc.) with auto-adjustable in-field reconfigurable sensors (e.g., auto-adjustable in-field reconfigurable pressure sensor, auto-adjustable in-field reconfigurable flow sensor, auto-adjustable in-field reconfigurable torque sensor, auto-adjustable in-field reconfigurable power consumption sensor, etc.). Further disclosed are exemplary embodiments of systems including controllers and auto-adjustable in-field reconfigurable sensors. Also disclosed are exemplary methods of automatically adjusting/reconfiguring sensors in the field to have narrower more focused sensor ranges, thereby increasing sensor resolution.