Industrial Sensor Module With Integrated Flow Diagnostics
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Solution Overview
Problem
Industrial sensor modules for pressurized fluid treatment in fluidic systems lack advanced diagnostic capabilities to effectively monitor and analyze flow and pressure data, leading to inefficiencies and potential operational issues in fluidic consumers.
Innovation Solution
An industrial sensor module equipped with a computing unit that generates diagnostic information based on flow values, pressure, and temperature data, utilizing a flow sensor, pressure sensor, and digital communication interface to provide real-time monitoring and diagnostic functions, such as operating state discrimination, flow monitoring, and pressure drop monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a computing unit with diagnostic functions is added to the sensor module, then diagnostic capability and operational efficiency are improved, but device complexity increases
Solution Approach 1:
The computing unit is integrated directly into the sensor module housing, merging diagnostic processing capabilities with the sensing function. This combination allows the module to perform flow detection and diagnostic analysis in a single integrated unit, improving reliability without requiring separate external processing equipment.
Solution Approach 2:
The computing unit is designed to perform multiple functions including flow value processing, diagnostic information generation, and communication via digital interface. This multi-functionality allows a single component to handle various operational aspects, enhancing diagnostic capability while managing complexity through functional integration.
2Productivity
If real-time flow monitoring and diagnostic functions are implemented, then operational efficiency and issue detection are improved, but energy consumption increases
Solution Approach 1:
The computing unit processes flow values and generates diagnostic information autonomously within the sensor module, enabling self-monitoring and self-diagnosis capabilities. This self-service approach allows real-time operational efficiency improvement without requiring continuous external system intervention, thereby managing energy consumption more effectively.
3Measurement precision
If diagnostic information generation based on flow values is implemented, then measurement precision and issue detection are improved, but device complexity increases
Solution Approach 1:
The computing unit continuously processes flow values from the flow sensor and generates diagnostic information that feeds back into system operation. This feedback mechanism enables precise measurement and real-time issue detection by comparing measured values against expected operational parameters, improving measurement precision through systematic analysis.
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
Enhances operational efficiency by providing accurate diagnostic information, enabling timely detection of issues like leakage, contamination, and pressure drops, thereby improving the reliability and performance of fluidic consumers.
Implementation Method 1
a flow sensor for detecting a pressurized fluid flow from the pressurized fluid inlet (15) to the pressurized fluid outlet (17) to provide one or more flow values
Implementation Method 2
detecting the pressurized fluid flow and generating the diagnostic information. Optionally, in the method, the pressure, the temperature and/or variables that can be derived therefrom
Data Source
AI summary
An industrial sensor module, in particular for use in a maintenance assembly for the pressurized fluid treatment of a fluidic system. The sensor module includes a module housing, a pressurized fluid inlet arranged on the module housing, a pressurized fluid channel arranged in the module housing and a pressurized fluid outlet arranged on the module housing and fluidically connected to the pressurized fluid inlet via the pressurized fluid channel, and a sensor device arranged in the module housing with a flow sensor for detecting a pressurized fluid flow from the pressurized fluid inlet to the pressurized fluid outlet in order to provide one or more flow values. The sensor module further includes a computing unit arranged in the module housing, which is designed to provide at least one diagnostic function for generating diagnostic information on the basis of the one or more flow values.