Wireless Industrial Sensor Data Transmission with Time-Gated Estimation
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Solution Overview
Problem
Industrial wireless data transmission systems for process control face challenges with high latency and reliability issues due to data interruptions and noisy environments, particularly in mechanical systems where traditional re-transmission methods can lead to loss of reliability and increased power consumption.
Innovation Solution
A wireless data transmission system that uses time-gated intervals for data transmission, employs a processor to estimate process parameters in case of data loss, and issues an emergency stop signal when a predetermined count of lost data is reached, incorporating a position sensor and radio transceivers with ISM band communication and Manchester encryption to maintain low latency and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If data re-transmission is used to assure data reliability, then data integrity is improved, but latency increases and reliability is lost when transmissions are dropped
Solution Approach 1:
The system performs preliminary actions by storing multiple recent process parameter values before data loss occurs. When data is dropped, the receiver uses these pre-stored values to generate estimates immediately without waiting for re-transmission, thereby maintaining reliability while avoiding latency penalties.
Solution Approach 2:
The receiver creates copies of previously received valid data and uses these copies to generate estimated values when current data is lost. This copying approach allows the system to maintain continuous operation with reliable estimates without requiring time-consuming re-transmission of original data.
2Loss of information
If data re-transmission is implemented to recover dropped data, then data completeness is improved, but system complexity and power consumption increase
Solution Approach 1:
Instead of implementing complex re-transmission protocols, the system simply copies and stores recent valid data values at the receiver. These copies are then used to generate estimates when data is dropped, providing a complete data stream without the complexity of re-transmission mechanisms.
Solution Approach 2:
The system uses simple, inexpensive estimation based on stored historical values rather than expensive, complex re-transmission protocols. The stored data values act as disposable resources that can be consumed to generate estimates without requiring sophisticated recovery mechanisms.
3Reliability
If higher power transceiver systems are used to assure communications continuity in noisy environments, then communications reliability is improved, but power consumption increases
Solution Approach 1:
The receiver copies and stores recent valid data values to generate estimates when communications are interrupted by noise or interference. This approach maintains communications reliability without requiring higher power transceivers, as the estimation mechanism compensates for dropped transmissions.
Solution Approach 2:
The system uses low-power estimation based on stored historical values rather than high-power transceiver systems to ensure communications continuity. The stored data values serve as a low-energy resource that enables reliable operation in noisy environments without increasing power consumption.
4Reliability
If data encryption and encoding for error correction are implemented, then data security is improved, but processing complexity and latency increase
Solution Approach 1:
The system performs preliminary actions by storing multiple recent process parameter values before data loss or security issues occur. When data is dropped or corrupted, the receiver uses these pre-stored values to generate estimates immediately, maintaining security and reliability without the latency of complex error correction processing.
Data Source
AI summary
A wireless data transmission system incorporates a process sensor providing an output for process monitoring data with a transmitter connected to the output of the sensor and transmitting the data in time gated intervals. A receiver receives the data from the transmitter and a determination is made if new data is received at a gated time interval. A processor connected to the receiver calculates process parameters based on the data received and a set of the calculated process parameters is stored. The processor estimates process parameters based on the stored set of calculated process parameters responsive to a signal from the determination that data packets have not been received at the gated interval. The process parameters front actual data, if present, or from the estimates made by the processor are then output for process control. A counter responsive to the determination of lost data, provides an emergency stop signal upon reaching a predetermined number of counts.