Universal Sensor Controller for Multi-Source Data Collection
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Solution Overview
Problem
Existing factory automation systems are costly and time-consuming to implement and manage, especially when integrating different types of sensors, limiting their use in small and medium-sized businesses due to the need for custom infrastructure and complex connections.
Innovation Solution
A modular sensor controller and communication module system that can collect and transmit operation data from various sensors, allowing for easy addition or replacement of sensors and automatic firmware updates, ensuring compatibility and efficient data collection regardless of sensor type.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a factory automation system is implemented with specifically designed measurement sensors for a certain company's products, then the measurement function is specialized and accurate, but the infrastructure cost and system complexity increase significantly
Solution Approach 1:
The sensor controller is designed to universally support multiple types of measurement sensors (temperature, humidity, pressure, etc.) through a standardized interface. The controller automatically recognizes and adapts to different sensor types without requiring custom infrastructure, thereby reducing system complexity while maintaining measurement precision through type-specific processing algorithms.
Solution Approach 2:
The system separates the measurement function into independent modular components: measurement sensors, sensor controller, and server. This segmentation allows each component to be optimized independently while communicating through standardized protocols, reducing overall system complexity and enabling flexible reconfiguration.
2Adaptability or versatility
If additional measurement sensors are added to an existing factory automation system, then the monitoring capability is enhanced, but the cost and time for manufacturing and developing new combined devices increase
Solution Approach 1:
The sensor controller implements universal compatibility with multiple sensor types through a standardized interface protocol. When a new measurement sensor is added, the controller automatically recognizes it and configures the appropriate processing parameters, eliminating the need to manufacture custom combined devices and significantly reducing manufacturing costs.
Solution Approach 2:
The system dynamically adapts to new sensor types through automatic recognition and configuration. The sensor controller can dynamically adjust its processing algorithms and communication parameters based on the detected sensor type, enabling flexible expansion without fixed device configurations.
3Adaptability or versatility
If measurement sensors from different manufacturers are integrated into a factory automation system, then the system flexibility is improved, but the integration complexity and time required for setting increase
Solution Approach 1:
The sensor controller implements self-service functionality by automatically recognizing measurement sensors from different manufacturers and configuring the appropriate processing parameters without manual intervention. The system performs automatic sensor identification, parameter matching, and integration setup, thereby eliminating time-consuming manual configuration while maintaining flexibility in sensor selection.
Solution Approach 2:
The system uses feedback mechanisms where the sensor controller continuously monitors sensor responses and automatically adjusts configuration parameters based on the actual sensor behavior. This closed-loop approach enables rapid adaptation to different sensor types from various manufacturers without requiring extensive pre-programming or manual setup.
Data Source
AI summary
According to the present disclosure, a sensor controller configured to collect a variety of machine related operations data may receive operation data from at least one measurement sensor connected to a machine and configured to detect the operation data of the machine and transfer the operation data to a communication module to be transmitted to and collected by a server. Even if a different measurement sensor is connected to a sensor controller, the operation data of the connected measurement sensor can be still recognized.