Smart Sensor Mode Switching for Real-Time Anomaly Detection
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Solution Overview
Problem
Existing industrial automation control systems face inefficiencies in processing sensor data in real-time, leading to delayed monitoring and control actions, as they rely on batch processing that requires significant computational resources and time.
Innovation Solution
Implementing smart sensor devices with processing capabilities that enable real-time or near-real-time processing of sensor data using learning algorithms, allowing them to toggle between operational modes for anomaly detection, preventative maintenance, and data validation, thereby reducing the need for external processing and conserving energy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If batch processing is used to process sensor data, then manufacturing precision is improved, but productivity deteriorates
Solution Approach 1:
The patent segments the sensor data processing into two distinct parts: (1) smart sensor devices perform real-time preprocessing, anomaly detection, and validation locally; (2) the control system performs batch processing only on validated data subsets. This segmentation allows both real-time responsiveness and accurate modeling to coexist, resolving the contradiction between processing speed and model accuracy.
2Reliability
If smart sensor devices operate continuously in high-processing mode, then reliability is improved, but use of energy worsens
Solution Approach 1:
The patent implements dynamic operational modes for smart sensor devices that can switch between low-power monitoring and high-processing anomaly detection based on operational conditions. The processor adjusts its processing intensity dynamically, performing comprehensive analysis only when anomalies are detected or during critical operational phases, thereby maintaining reliability while reducing overall energy consumption.
3Measurement precision
If all sensor data is transmitted for external processing, then measurement precision is improved, but device complexity worsens
Solution Approach 1:
The patent extracts and removes invalid or low-quality sensor data at the source through validation algorithms implemented in smart sensor devices. By filtering out erroneous data before transmission, the system reduces the burden on external processing systems and communication networks, thereby reducing overall system complexity while maintaining measurement precision for valid data.
4Productivity
If real-time processing is implemented, then productivity is improved, but use of energy worsens
Solution Approach 1:
The patent applies partial processing in real-time at the smart sensor level, performing only essential functions such as data validation, basic anomaly detection, and filtering. More comprehensive analysis is performed selectively on subsets of validated data by the control system. This partial real-time processing maintains productivity while avoiding the excessive energy consumption that would result from full real-time processing at all levels.
Data Source
AI summary
A system may include sensor device comprising a sensor configured to measure sensor data indicating an operational parameter of industrial automation equipment associated with an industrial automation process. The system may also include communication circuitry configured to transmit the sensor data. Additionally, the system includes a processor configured to receive the sensor data. Further, the system includes a non-transitory computer-readable medium comprising computer-executable instructions that, when executed, are configured to cause the processor to perform operations including identifying an operational state of the industrial automation equipment based on the sensor data. The operations may also include determining a discrepancy between the sensor data and the operational state. Further, the operations may include modifying an operation of the processor from a first operational mode to a second operational mode of a plurality of operational based on the comparison.


