Sensor Module Automatic Calibration for Inclined Installation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing sensor modules for detecting material containers in storage or transport systems require external readjustment when installed at inclined positions, and previous solutions for adapting to fluctuating ground conditions are resource-intensive and unable to adapt to different stationary installation positions.

Innovation Solution

A sensor module that automatically adjusts its switching angle based on the measured angle relative to a fixed direction, using off and on free pivot angles to maintain stable switching states without external adaptation, allowing it to adapt to various installation positions and inclinations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the sensor module uses a fixed switching angle calibrated for horizontal installation, then the switching point position is stable at horizontal installation, but the switching point position changes with inclination requiring external readjustment

Engineering Contradiction:

Improveswitching point position accuracyVSAvoidinstallation position adaptability

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The sensor module performs automatic self-calibration by detecting its own installation inclination and adjusting the switching angle accordingly. The control unit measures the actual pivot angle range through calibration cycles and autonomously sets the switching angle to the midpoint, eliminating the need for external readjustment and enabling adaptation to any installation position while maintaining switching point accuracy

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system dynamically changes the switching angle parameter based on the measured installation inclination. During calibration, the control unit determines the actual pivot angle range and calculates an appropriate switching angle that accounts for the installation position, thereby maintaining stable switching behavior across different installation scenarios

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If manual external readjustment is used for inclined installation positions, then switching point accuracy can be maintained, but operational complexity and maintenance requirements increase

Engineering Contradiction:

Improveswitching point position accuracyVSAvoidinstallation and maintenance simplicity

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The sensor module automatically calibrates itself upon installation or when triggered by power-on events. The control unit executes calibration routines that detect the installation inclination and adjust the switching angle without requiring external intervention, thereby maintaining switching point accuracy while eliminating the need for manual readjustment and simplifying operation and maintenance

Inventive Principle:

Principle #25Self-service

3Adaptability or versatility

If automatic calibration is implemented, then adaptability to different installation positions is achieved, but computational power and storage capacity requirements increase

Engineering Contradiction:

Improveinstallation position adaptabilityVSAvoidcomputational and storage resource consumption

Core Design Contradiction:

Adaptability or versatilityVSUse of energy by moving object

Solution Approach 1:

The calibration function is activated only when necessary (e.g., upon power-on or when installation position changes are detected) rather than continuously. The control unit performs measurements and calculations only during these specific moments, reducing overall computational and storage resource consumption while still achieving full adaptability to different installation positions

Inventive Principle:

Principle #16Partial or excessive action

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 sensor module automatically readjusts its switching point to maintain reliable operation across different installation positions and inclinations, eliminating the need for external adjustments and reducing computational and storage demands.

Implementation Method 1

The angle can be measured, for example, relative to a direction of a weight force, i.e., relative to a perpendicular

Methodology Applied

Scientific EffectGravitation: Gravitation

Data Source

PatentUS11802890B2Method for automatically calibrating a sensor module and sensor module for detecting material containers in a storage or transport system

Publication Date: 2023.10.31 STEUTE TECH GMBH & CO KG

AI summary

A method for automatically calibrating a rocker-type sensor module having a position or acceleration sensor involves measuring a position of the sensor module as an angle relative to a fixed spatial direction, and outputting an output signal that depends on whether the measured angle is less than or greater than a switching angle. The output signal is set to a first output value if the measured angle exceeds the switching angle. The switching angle is set to a value corresponding to the measured angle minus an “off” free pivot angle, as long as the value of the measured angle continues to increase. The output signal is set to a second output value if the measured angle falls below the switching angle. The switching angle is set to a value corresponding to the measured angle plus an “on” free pivot angle, as long as the value of the measured angle continues to fall.