Sensor System Timing Correlation for Workpiece State Detection
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Solution Overview
Problem
In existing sensor systems, the independent use of data from multiple sensors makes it difficult to determine positional relationships and detect changes such as positional deviations or falling of workpieces during the conveyance process, as the master unit lacks information about the measurement times of each sensor's data.
Innovation Solution
A sensor system with a master unit that stores data in association with timing information, allowing for comparison of data from multiple sensors to determine changes in the workpiece's state, including positional deviations and conveyance speed, using a determination part that calculates timings based on conveyance speed and sensor positions, and optionally employs machine learning for accurate state determination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If data from multiple sensors is used independently without timing information, then the system structure is simple, but the ability to determine positional relationships and detect changes in workpiece state deteriorates
Solution Approach 1:
The master unit pre-stores timing information for each slave unit in advance. When data is received from sensors, the master unit can immediately correlate the data with the pre-stored timing information to determine positional relationships, eliminating the need for complex real-time calculations while maintaining high measurement precision.
Solution Approach 2:
Timing information acts as an intermediary element that bridges the gap between sensor data and positional relationship determination. The master unit uses this intermediary timing data to accurately correlate measurements from multiple sensors without requiring direct complex interactions between all sensor components.
2Reliability
If timing information is stored and processed for each sensor data, then the ability to detect changes in workpiece state improves, but the data processing complexity and storage requirements increase
Solution Approach 1:
The master unit pre-stores timing information for each slave unit before data collection begins. This preliminary preparation allows the system to efficiently correlate sensor data with timing information during operation, improving reliability in detecting workpiece state changes without requiring complex real-time processing.
Solution Approach 2:
Each slave unit autonomously generates and transmits its own timing information along with sensor data. The master unit simply receives and correlates this self-contained data packets, reducing the processing burden on the master unit while maintaining high reliability in detecting workpiece state changes.
3Productivity
If data is transmitted without waiting for commands to improve communication speed, then communication efficiency improves, but the synchronization and coordination between master and slave units becomes more difficult
Solution Approach 1:
The master unit transmits periodic trigger signals to all slave units at regular intervals. Each slave unit uses these periodic triggers as a reference point to transmit their sensor data at predetermined timings, enabling continuous high-speed communication while maintaining synchronization through the periodic nature of the trigger signals.
Solution Approach 2:
The master unit receives data from slave units and uses the stored timing information to determine positional relationships and detect workpiece state changes. This feedback loop allows the system to maintain synchronization by continuously monitoring and correlating the timing of received data with the expected timing based on periodic triggers.
Data Source
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AI summary
An objective of the present invention is to provide a sensor system with which a change in the state of a workpiece which has occurred in a conveyance process can be determined. Provided is a sensor system comprising: a plurality of sensors positioned along a line and measuring data indicating that a workpiece being conveyed upon the line has passed thereby; a plurality of slave units respectively connected to the plurality of sensors and acquiring the data measured by the plurality of sensors; and a master unit connected to the plurality of slave units. The master unit comprises: a storage part for storing the data in association with information which relates to the timing at which the data was measured; and a determination part for comparing the data transmitted from two or more of the plurality of slave units using the information which relates to the timing, and determining a change in the state of the workpiece.