Portable Sensor Placement System Using Image Orientation Analysis
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Solution Overview
Problem
Inconsistent placement of portable vibration sensors on machines leads to inaccurate readings, as different individuals may position the sensors differently, causing variations that can be misattributed to changes in machine condition rather than sensor placement errors.
Innovation Solution
A sensor placement system using a camera, accelerometer, and graphical user interface (GUI) to guide users in consistently mounting sensors by recording images, determining orientations, and comparing them to reference orientations, ensuring accurate and reproducible sensor placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a portable vibration sensor is temporarily attached to different machines, then the sensor can be used infrequently and moved between machines, but the sensor placement becomes inconsistent leading to inaccurate readings
Solution Approach 1:
The system captures reference images of the machine surface before sensor attachment and uses these to calculate precise placement coordinates. This preliminary action ensures that when the sensor is temporarily attached and removed, it can be repositioned accurately on the same or different machines, maintaining measurement precision while enabling sensor reusability
Solution Approach 2:
The system creates a digital copy of the machine surface geometry through image capture and processing. This digital model serves as a template that guides sensor placement, allowing the sensor to be consistently positioned on different machines or at different times without manual measurement, thus maintaining accuracy while enabling portable sensor usage
2Ease of operation
If different individuals position the portable sensor, then the sensor can be deployed flexibly, but placement consistency deteriorates causing measurement variations
Solution Approach 1:
The system enables any user to achieve precise sensor placement without requiring specialized training or expertise. The automated image-based positioning system guides the user through the process, automatically calculating coordinates and providing visual feedback, thus maintaining placement consistency while allowing flexible deployment by different individuals
Solution Approach 2:
The system provides real-time visual feedback through the mobile device display, showing the user the calculated sensor placement position overlaid on the captured image. This feedback loop allows users to adjust their placement approach while ensuring consistency with the predetermined coordinates, maintaining both ease of operation and placement stability
3Adaptability or versatility
If sensor placement location varies, then different measurement points can be explored, but measurement accuracy decreases due to placement variations being misattributed to machine condition changes
Solution Approach 1:
The system pre-determines optimal sensor placement coordinates based on the machine geometry captured in reference images. These predetermined coordinates ensure that sensors are always placed at consistent, meaningful locations, allowing reliable comparison of measurements over time while still enabling exploration of different measurement points by selecting different coordinate sets for different machines or monitoring locations
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
This approach enhances the accuracy and reliability of sensor measurements by ensuring consistent sensor placement, reducing errors attributed to placement variations and improving asset monitoring systems.
Implementation Method 1
recording, using a camera, a first image at a first resolution that includes a first sensor placed on a target
Implementation Method 2
determining, using an accelerometer, an orientation of the first image concurrently with the recording of the first image
Data Source
AI summary
A method for consistently mounting a removable sensor to a machine is provided. The method includes recording, by camera, an image including a sensor placed on a target. The sensor includes a first plane marked with a first color that is perpendicular to a first sensor axis representing a positive axis direction. The method also includes determining, by accelerometer, an image orientation concurrently with the recording. The method further includes identifying the sensor within the image. The method additionally includes determining, using the identified first color, a sensor orientation within the image relative to the image orientation. The sensor orientation includes the positive axis direction. The method also includes comparing the sensor orientation to a reference orientation. The method further includes determining the sensor orientation matches the reference orientation and recording a target measurement in response. The method also includes outputting, by GUI, confirmation of that the measurement was recorded.