Sensor Output Correction Using Position-Based Misalignment Adjustment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Data acquisition sensors, such as vibration sensors, often experience misalignment due to assembly errors, tolerances, and mounting limitations, leading to inaccurate data collection and potential misdiagnosis of asset conditions.
Innovation Solution
The use of a position sensor with a movable portion, such as a potentiometer, to measure and adjust the offset between the sensor and the asset, allowing for accurate data collection by transforming sensor output based on the measured offset.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If physical alignment features and precise mounting are used to ensure accurate sensor orientation, then measurement precision is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent replaces mechanical alignment features with an electronic/software-based solution. A position sensor detects the actual physical orientation of the data acquisition sensor, and programmable circuitry automatically calculates and applies correction factors to transform the sensor output data. This substitutes complex mechanical alignment mechanisms with an electronic detection and computational correction system, reducing device complexity while maintaining measurement precision.
Solution Approach 2:
The patent changes the orientation parameter of the sensor output data through mathematical transformation. Instead of physically realigning the sensor, the system detects the offset orientation and applies a coordinate transformation to the measured data, effectively changing the reference frame parameters to match the asset's coordinate system. This allows accurate measurements without complex physical alignment.
2Measurement precision
If manual alignment procedures are performed to correct sensor misalignment, then measurement precision is improved, but loss of time and productivity decrease
Solution Approach 1:
The system performs self-alignment through automated detection and correction. The position sensor automatically detects the offset between the sensor coordinate system and the asset coordinate system, and the programmable circuitry automatically calculates and applies the necessary transformation factors. This eliminates the need for manual alignment procedures, reducing installation time and enabling the system to self-correct without human intervention.
Solution Approach 2:
The system uses feedback from the position sensor to automatically adjust the sensor output interpretation. The position sensor provides real-time information about the actual sensor orientation, and this feedback is used by the programmable circuitry to dynamically apply correction factors. This closed-loop feedback mechanism eliminates the need for time-consuming manual alignment procedures while ensuring measurement accuracy.
3Manufacturing precision
If tolerances and assembly variations are minimized to ensure proper sensor alignment, then manufacturing precision is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The patent replaces mechanical precision requirements with an electronic compensation system. Instead of requiring tight manufacturing tolerances for sensor alignment, the system uses a position sensor to detect the actual assembly orientation and programmable circuitry to automatically calculate correction factors. This substitutes mechanical precision requirements with electronic detection and computational correction, significantly easing manufacturing requirements.
Solution Approach 2:
The system compensates for manufacturing variations by changing the interpretation parameters of the sensor data. The position sensor detects the actual orientation caused by assembly tolerances, and the programmable circuitry applies transformation factors to the output data. This allows the system to accept a wide range of manufacturing tolerances while maintaining measurement accuracy through parameter transformation rather than requiring tight manufacturing control.
Data Source
AI summary
Methods and apparatus for electronic sensor adjustment are disclosed. A disclosed example sensor device for use with an asset includes a housing to be coupled to the asset, a data acquisition sensor to provide first sensor output, a position sensor to provide second sensor output, the position sensor having a movable portion, and programmable circuitry to execute instructions to determine, based on the second sensor output, an offset of the movable portion for adjustment of the first sensor output, and adjust the first sensor output based on the offset.