Thermal Camera Assembly Single Cable Control
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Solution Overview
Problem
Existing thermal cameras used in industrial environments, such as foundries, require thick multipolar cables for power and signal transmission, making it difficult to navigate through obstructed spaces due to the need for individual connections for each component, leading to bulky connectors and installation challenges.
Innovation Solution
A thermal camera assembly with an integrated control unit that uses a single electric cable for power supply and digital data transmission, eliminating the need for multiple connections and allowing the camera to operate independently with a compact design, including a control unit that manages communication and component control within the protective casing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If individual electrical connections are provided for each component (sensor and actuator) housed in the thermal camera, then each component can be independently connected to the remote controller, but a thick multipolar cable with large diameter is required which is difficult to run in industrial plants
Solution Approach 1:
The patent merges multiple individual electrical connections for sensors and actuators into a single integrated control unit. This control unit consolidates all signal processing and control functions, allowing communication through a single cable with small diameter instead of requiring a thick multipolar cable for each component connection.
Solution Approach 2:
The control unit is designed as a universal interface that handles all communication between the thermal camera components and the remote controller. It manages power supply, signal transmission, and data processing for multiple components through a single standardized connection, eliminating the need for multiple dedicated cables.
2Adaptability or versatility
If a thick multipolar cable is used to connect all components individually, then all sensors and actuators can be connected, but the cable requires large bending radius and is difficult to navigate through obstructed spaces
Solution Approach 1:
Multiple cable connections are merged into a single cable connection by integrating all component interfaces into one control unit. This single cable has small diameter and can be easily routed through tight spaces and around obstacles in industrial environments.
Solution Approach 2:
The control unit acts as an intermediary device that receives a single cable connection and distributes connections to multiple internal components. It mediates between the simple single-cable external interface and the complex internal component network, enabling easy installation while maintaining full component connectivity.
3Temperature
If a pneumatic connection is provided for compressed air supply to the cooling system, then the thermal camera can be cooled effectively, but the system becomes more complex and requires additional connections
Solution Approach 1:
The pneumatic connection for compressed air supply is extracted and replaced with an electrical control system. The control unit electrically controls the cooling system (such as a Peltier element or electronic fan) instead of using pneumatic actuators, eliminating the need for pneumatic connections while maintaining cooling effectiveness.
Solution Approach 2:
The mechanical pneumatic system is replaced with an electrical control system. Electrical signals from the control unit drive electronic cooling components, substituting the pneumatic mechanism and reducing system complexity by eliminating pneumatic connections and components.
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
The solution reduces the cable thickness and curvature radius requirements, simplifying installation and movement in industrial settings, while also enabling autonomous processing of thermographic images and reducing energy consumption by eliminating the need for a pneumatic connection and minimizing compressed air usage.
Implementation Method 1
a thermal imaging detector (3) sensitive to infrared radiation
Implementation Method 2
a vortex tube (23), placed outside the protection casing, which allows to separate a high pressure fluid into two jets which have very different temperature
Data Source
AI summary
Thermal camera assembly (1) comprising a thermal imaging detector (3) providing thermographic images and/or recordings, a protective casing (2) which houses the thermal imaging detector and includes a window (5) with a transparent screen (6), one or more sensors (15;16;20;32;33) arranged in the protective casing and providing signals indicative of a physical quantity or a state, one or more actuators (8;22;28) arranged in the protective casing, and a control unit (9) which is integrated in the protective casing. The control unit is directly connected to the thermal imaging detector to receive the thermographic images and/or recordings and transmit them to the outside, to the sensors to receive the relative signals, and to the actuators to control the latter according to the signals received. The control unit is able to manage and control the communication between all the components of the thermal camera and the outside. The thermal camera assembly is part of a control system for controlling an industrial production process and is used in a relative control method.