Wireless Sensor Commissioning for Faster Industrial Drive Tuning
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Solution Overview
Problem
The commissioning of industrial drives is often labor-intensive and time-consuming, requiring extensive trial-and-error adjustments of drive parameters to achieve optimal performance, which can be inefficient and prone to suboptimal results.
Innovation Solution
A method and system utilizing wireless sensor devices and a computing device to establish a local wireless communications network, allowing for synchronized drive control sequences and sensor measurement sequences, enabling real-time data collection and adjustment of drive parameters for improved industrial process control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional trial-and-error commissioning method is used, then drive parameters can be adjusted to achieve optimal performance, but the commissioning process becomes time-consuming and labor-intensive
Solution Approach 1:
The system performs preliminary measurements and assessments during commissioning to predict optimal drive parameters before actual operation. Sensors collect data about the controlled machine and process conditions, and the system pre-calculates suitable parameter settings, avoiding time-consuming trial-and-error adjustments during field commissioning.
Solution Approach 2:
The system continuously monitors drive performance and process parameters using sensors, compares actual results with target values, and automatically adjusts drive parameters based on feedback. This closed-loop approach enables rapid optimization without manual trial-and-error, significantly reducing commissioning time while maintaining optimal performance.
2Manufacturing precision
If extensive testing is performed during commissioning, then optimal drive parameters can be determined, but the complexity of the commissioning process increases
Solution Approach 1:
The commissioning system performs self-configuration and self-optimization by automatically collecting data from sensors, analyzing process requirements, and determining optimal drive parameters without extensive manual testing. The system serves itself by using embedded sensors and automated algorithms to complete the commissioning process, reducing both testing requirements and process complexity.
Solution Approach 2:
The system replaces manual trial-and-error adjustment mechanisms with automated electronic control and data analysis. Sensors and computing devices substitute for human operators in performing measurements and parameter adjustments, simplifying the commissioning process while maintaining high precision in parameter optimization.
3Reliability
If manual commissioning with trial and error is used, then expertise is required to adjust parameters, but the ease of operation during commissioning is reduced
Solution Approach 1:
The commissioning system performs self-configuration and self-optimization by automatically collecting data from sensors, analyzing process requirements, and determining optimal drive parameters without extensive manual testing. The system serves itself by using embedded sensors and automated algorithms to complete the commissioning process, reducing both testing requirements and process complexity.
Solution Approach 2:
The system introduces a computing device as an intermediary between the drive and the operator. This intermediary automatically processes sensor data, determines optimal parameters, and communicates results to the user, eliminating the need for operators to possess deep expertise while maintaining high commissioning quality. The intermediary translates complex technical adjustments into simple automated operations.
Data Source
AI summary
According to an aspect, there is provided method for commissioning a drive. First, a local network is established between a wireless computing device, one or more wireless sensor devices and a drive. Each wireless sensor device is configured to measure one or more physical quantities associated with an industrial system controlled by the drive. The wireless computing device configures wirelessly the drive and the one or more wireless sensor devices for performing measurements. In response to receiving one or more measured values from the one or more wireless sensor devices, the wireless computing device displays the information on the one or more measured values on a display for providing guidance for a user of the wireless computing device for adjusting drive parameters of the drive.