Portable Sensor Placement Verification Using Image Orientation
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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 positioning 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 mounted on a machine by different individuals, then the sensor can be reused on multiple machines, but the sensor placement location and orientation vary, leading to inconsistent measurements
Solution Approach 1:
The system captures a reference image of the machine surface at the correct sensor placement location and orientation before actual sensor mounting. This preliminary visual record serves as a guide for subsequent sensor placements, ensuring that different individuals can reproduce the same placement position and orientation accurately, thus maintaining measurement consistency while enabling sensor reusability
Solution Approach 2:
The system creates a visual copy (image) of the correct sensor placement location and orientation on the machine. This image copy is stored and used as a reference template that can be repeatedly viewed and followed by different individuals, allowing them to replicate the exact same sensor placement without requiring physical presence of the original placement, thereby ensuring measurement consistency across multiple uses
2Ease of operation
If sensor placement is left to individual judgment without guidance, then the mounting process is simple and quick, but the sensor placement varies between individuals and over time
Solution Approach 1:
The system enables the machine itself to provide the placement guidance by capturing an image of its own surface with the correct sensor location marked or indicated. The machine's visual information serves the function of guiding placement, eliminating the need for external complex fixtures or tools, thus maintaining ease of operation while improving placement repeatability through the standardized visual reference
3Measurement precision
If detailed documentation of sensor placement is created and stored, then placement consistency can be verified, but the system complexity and data storage requirements increase
Solution Approach 1:
Instead of creating complex detailed documentation, the system uses a simple image copy of the sensor placement location and orientation. This visual copy is easy to capture, store, and retrieve, providing sufficient information for placement verification without requiring complex documentation systems, thus improving placement accuracy while minimizing system complexity
Solution Approach 2:
The system replaces complex mechanical placement fixtures, alignment tools, or physical guides with a digital image-based guidance system. The image serves as a virtual reference that can be viewed on a display device, eliminating the need for physical placement aids while maintaining or improving placement precision, thereby reducing overall system complexity
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 inconsistencies 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 first image including a first sensor placed on a target can be recorded at a first resolution. Using an accelerometer, an orientation of the first image can be determined concurrently with recording of the first image. The orientation of the first image can be associated with an orientation of the first sensor placed on the target within the first image. A user input indicating a boundary surrounding the first sensor in a portion of the first image can be received via a graphical user interface (GUI). The orientation of the first sensor within the first image can be compared with a predetermined reference orientation and a determination made whether the orientation of the first sensor within the first image matches the predetermined reference orientation. When the orientation of the first sensor within the first image matches the predetermined reference orientation, a confirmation can be output via the GUI.