Twin Sensor Parameter Inheritance for Fast Accurate Replacement
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Solution Overview
Problem
In manufacturing industries, replacing defective sensors quickly and efficiently is challenging due to the variety of mechanical, functional, and configurable properties, which complicates the classification and configuration of replacement sensors.
Innovation Solution
A method for generating a 'twin sensor' using parameter inheritance, where a unique generation code is created to facilitate the production of an identical replacement sensor, allowing configuration parameters and mechanical/electrical features to be transferred wirelessly or via a mobile device, enabling easy replacement without manual reconfiguration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If sensors are replaced manually with configuration transfer, then replacement accuracy can be maintained, but replacement time and complexity increase
Solution Approach 1:
The patent creates a digital twin (virtual copy) of the sensor that contains all configuration parameters, mechanical properties, and electrical characteristics. This digital copy enables automated generation of replacement sensors with identical specifications, eliminating manual configuration transfer while maintaining precision.
Solution Approach 2:
The system pre-generates a digital twin of the sensor before replacement is needed, storing all necessary configuration data in advance. When replacement is required, the pre-prepared digital twin is immediately used to configure the new sensor, eliminating the time-consuming manual configuration process.
2Manufacturing precision
If comprehensive sensor parameters are tracked, then twin sensor accuracy improves, but data management complexity increases
Solution Approach 1:
The patent creates a universal digital twin model that can represent any sensor type with a standardized data structure. This single approach handles diverse sensor parameters (mechanical, electrical, configuration) uniformly, reducing data management complexity while maintaining comprehensive tracking for accurate twin generation.
Solution Approach 2:
The system transforms complex sensor parameters into a standardized parameter set for the digital twin, converting diverse mechanical, electrical, and configuration properties into a unified data format that is easier to manage and process while preserving all necessary information for accurate replication.
3Device complexity
If manual configuration transfer is used, then system simplicity is maintained, but labor intensity and error risk increase
Solution Approach 1:
The system enables self-service configuration where the digital twin automatically provides all necessary configuration data for replacement sensor setup. The automated process eliminates manual intervention, reducing labor intensity and human error while keeping the overall system architecture simple and intuitive.
4Productivity
If quick sensor replacement is achieved, then production downtime is reduced, but configuration accuracy may compromise
Solution Approach 1:
The digital twin serves as a precise digital copy containing all configuration parameters, enabling rapid automated configuration of replacement sensors without sacrificing accuracy. The copy ensures exact replication of the original sensor's settings while eliminating time-consuming manual processes.
Data Source
Figure 1
AI summary
A method for generating a twin sensor by means of parameter inheritance is proposed, wherein the twin sensor is suitable to replace a sensor (110), comprising the steps of: connecting a mobile device (120) to the sensor (110) to transmit signals; configuring the sensor (110) by means of the mobile device (120), wherein the configuration is based on configuration parameters that are transmitted to the sensor (110) by means of the mobile device (120); generating a unique generation code for the inheritance of the parameters by means of a configuration module, based on the configuration parameters; providing the generation code by means of the configuration module for generating the twin sensor by means of parameter inheritance, wherein the inheritance of the parameters is based on the generation code.