Distributed Smart Sensor Processing With Batch Channel Selection
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Solution Overview
Problem
Conventional condition monitoring systems require complex and costly installations due to individual cabling for analog sensors, and existing smart sensing systems are limited by resource-intensive processing requirements and high costs associated with DO-254 certification, necessitating a more efficient and cost-effective distributed sensing processing solution.
Innovation Solution
A smart sensor system incorporating multiple analog-to-digital converters (ADCs), channel modules with limited data processing, and a data control module that interfaces with external memory and batch processing modules, allowing for initial and further processing of data, with programmable logic devices (PLDs) for resource-intensive calculations, and separating processing into continuous and batched modes to optimize resource usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual cabling is used for each analog sensor, then sensor data can be transmitted to the host, but the system becomes heavy and installation becomes complicated
Solution Approach 1:
The system segments the processing function by introducing intermediate smart sensors that perform local digitization and preliminary processing. This divides the original centralized host processing into distributed processing nodes, eliminating the need for individual analog cabling to the host while reducing installation complexity.
Solution Approach 2:
Smart sensors act as intermediary devices between the analog sensors and the host system. These intermediaries perform local analog-to-digital conversion and preliminary processing, allowing multiple sensors to share communication bandwidth and reducing the complexity of individual cabling runs to the host.
2Productivity
If processing is distributed locally to sensors, then processing load on host is reduced, but the smart sensors require more complex processing capabilities
Solution Approach 1:
Processing is segmented into two levels: simple real-time processing at the smart sensor level (digitization, basic filtering) and complex batch processing at the host level. This segmentation allows smart sensors to remain relatively simple while still providing distributed processing benefits.
Solution Approach 2:
The system uses periodic batch processing at the host level to handle complex computations. Instead of requiring continuous complex processing at the sensor level, the smart sensors perform real-time preprocessing and the host periodically processes accumulated data in batches, reducing the processing requirements for smart sensors.
3Productivity
If programmable logic devices are used in smart sensors, then processing capability is improved, but the cost of DO-254 certification increases
Solution Approach 1:
The system changes the operational parameters of the PLD by using it in a fixed, predetermined sequence for batch processing rather than allowing dynamic reconfiguration. This fixed-operation approach simplifies certification requirements while maintaining processing capability.
Solution Approach 2:
The system uses cost-effective PLD implementations that prioritize functional capability over military-grade certification. By accepting that DO-254 certification is expensive and time-consuming, the design chooses PLDs that provide sufficient processing capability without requiring full certification, particularly for non-safety-critical batch processing functions.
4Productivity
If logical blocks are instantiated in PLD for specific calculations, then processing efficiency is improved, but the blocks are occupied and cannot be used for other calculations
Solution Approach 1:
The PLD logical blocks are configured to operate in periodic batch processing mode rather than continuous operation. Blocks are instantiated for specific calculation types and process accumulated data in sequences, allowing them to be reconfigured between batches for different processing tasks, thus maintaining both efficiency and flexibility.
Solution Approach 2:
The system introduces dynamic reconfiguration capability to the PLD, allowing logical blocks to be dynamically allocated and reconfigured based on processing requirements. This enables the same hardware resources to be adaptively assigned to different processing tasks over time, balancing efficiency with versatility.
Data Source
AI summary
A smart sensor can include a plurality of analog-to-digital converters (ADCs) configured to receive analog signals from a sensor module, and a plurality of channel modules. Each channel module can be connected to a respective ADC and each channel module can include a limited data processing module configured to provide initial processing. The sensor can include a data control module operatively connected to each of the plurality of channel modules and configured to select a selected channel of the plurality of channels to receive initially processed data from the limited data processing module of the selected channel. The data control module can be configured to interface with external memory to store data to the external memory and/or to read data from the external memory. The sensor can include a batch processing module operatively connected to the data control module and configured to receive the initially processed data of the selected channel from the data control module to provide further processing of the initially processed data.