Sensor Calibration Over Power Wires for Long-Cable Reliability
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Solution Overview
Problem
Existing sensor calibration methods require multiple specialized communication cables, increasing costs and risking product failure due to inability to recalibrate after assembly, with poor anti-interference performance and limited adaptability to long cables.
Innovation Solution
A communication method using a power supply wire to modulate and demodulate command signals, allowing calibration without additional cables and enhancing anti-interference capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If specialized communication cables are used for sensor calibration, then communication reliability is improved, but material costs and device complexity increase
Solution Approach 1:
The power supply wire is designed to serve dual purposes: delivering power to the sensor and transmitting calibration command signals. By integrating communication functionality into the existing power supply infrastructure, the patent eliminates the need for separate communication cables, reducing material costs and device complexity while maintaining calibration capability
Solution Approach 2:
The patent merges the power supply function and communication function into a single wire system. The power supply wire simultaneously carries both electrical power and modulated calibration signals, consolidating multiple functions into one component to reduce overall system complexity
2Productivity
If communication cables are cut during assembly, then production efficiency is improved, but the ability to recalibrate after assembly is lost
Solution Approach 1:
The calibration communication capability is established during sensor manufacturing by integrating the modulation/demodulation circuits into the sensor itself. This preliminary setup ensures that the sensor retains inherent communication capability through its power wire, allowing recalibration at any stage without requiring additional cables or modifications during assembly
Solution Approach 2:
The sensor is equipped with built-in modulation and demodulation circuits that enable it to communicate calibration commands and data through its own power supply wire. This self-contained design allows the sensor to perform calibration functions independently without external communication infrastructure, maintaining recalibration capability throughout its lifecycle
3Measurement precision
If multiple specialized cables are used for sensor communication, then communication precision is improved, but material costs increase
Solution Approach 1:
The power supply wire is designed to serve dual purposes: delivering power to the sensor and transmitting calibration command signals. By integrating communication functionality into the existing power supply infrastructure, the patent eliminates the need for separate communication cables, reducing material costs and device complexity while maintaining calibration capability
Solution Approach 2:
The patent introduces modulation and demodulation as intermediary processes that enable precise digital communication through the analog power supply wire. By encoding calibration commands onto voltage variations and decoding them at the sensor, the system achieves communication precision without requiring specialized communication cables
4Ease of operation
If existing communication methods are used, then ease of operation is maintained, but anti-interference performance deteriorates
Solution Approach 1:
The patent introduces modulation and demodulation as intermediary processes that enable precise digital communication through the analog power supply wire. By encoding calibration commands onto voltage variations and decoding them at the sensor, the system achieves communication precision without requiring specialized communication cables
Solution Approach 2:
The patent replaces traditional electrical signal transmission with a modulation-based communication system. By using voltage variation patterns instead of direct electrical signals, the system achieves better noise immunity and anti-interference performance while maintaining ease of operation through automated modulation/demodulation processes
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
Reduces material costs, prevents product scrap by enabling post-assembly recalibration, and improves communication reliability over varying cable lengths.
Implementation Method 1
modulating, by a calibration device, a command signal to be issued to the sensor into a voltage change signal. The voltage change signal is coupled onto the power supply wire of the sensor
Implementation Method 2
decoupling and demodulating the voltage change signal with the sensor to obtain the command signal
Data Source
AI summary
A communication method for calibrating a sensor based on a power supply wire of the sensor includes modulating, by a calibration device, a command signal to be issued to the sensor into a voltage change signal. The voltage change signal is coupled onto the power supply wire of the sensor and the sensor receives the voltage change signal from the power supply wire. The communication method includes decoupling and demodulating the voltage change signal with the sensor to obtain the command signal, processing, by the sensor, the command signal after the sensor receives the command signal, and sending a corresponding command reply back to the calibration device.