Wireless Measurement Chain for Fast Tool Change Reconnection
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Solution Overview
Problem
Existing measurement chains in manufacturing processes face challenges with high latency and cost due to frequent tool changes, requiring reconnection of sensors and antennas, which disrupt measurement accuracy and dynamic resolution, especially when using strain gauges with limited range and low dynamic measurement resolution.
Innovation Solution
A measurement chain with multiple units, each comprising a sensor, converter unit, and secondary antenna, automatically couples with an evaluation unit via a primary antenna, establishing a transmission connection to quickly reconnect and maintain high dynamic measurement resolution and accuracy across multiple process steps without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a strain gauge sensor is used in the measurement chain, then the measurement chain can be implemented with simple structure, but the dynamic measurement resolution is limited and measuring range is restricted
Solution Approach 1:
The patent changes the sensor type from strain gauge to piezoelectric sensor, which fundamentally alters the measurement parameters. Piezoelectric sensors provide higher dynamic measurement resolution and broader measuring range while maintaining structural simplicity through wireless transmission capabilities.
2Reliability
If the measurement chain is reconnected manually during tool changes, then connection reliability can be ensured, but the time latency increases and productivity decreases
Solution Approach 1:
The measurement chain implements self-service through automatic reconnection capabilities. The wireless transmission system with primary and secondary antennas automatically establishes connections during tool changes without manual intervention, ensuring both reliability and continuity while eliminating time latency.
3Adaptability or versatility
If multiple measurement units are used for multiple tools, then measurement coverage is improved, but the system complexity and cost increase
Solution Approach 1:
The patent implements universality by designing measurement units with standardized wireless transmission interfaces. Multiple measurement units can be used across different tools, but they all communicate through the same primary antenna system, reducing overall system complexity while maintaining broad measurement coverage.
4Ease of operation
If far-field telemetry is used for antenna transmission, then the antenna positioning flexibility is improved, but the transmission accuracy and signal quality deteriorate
Solution Approach 1:
The patent introduces an intermediary evaluation unit that receives signals from multiple secondary antennas via primary antenna. This intermediary system processes and consolidates transmission signals, maintaining high accuracy while allowing flexible antenna positioning through the wireless transmission architecture.
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
This solution enables rapid reconnection of the measurement chain with high accuracy and dynamic resolution, reducing latency and costs, as each measurement unit can be quickly positioned and connected, ensuring continuous measurement data transmission during tool changes in manufacturing processes.
Implementation Method 1
The measurement unit comprises a piezoelectric sensor, an electronic unit, and a moving antenna. The electronic unit conditions and/or compresses measurement signals from the piezoelectric sensor into measurement data.
Implementation Method 2
The moving antenna transmits the measurement data to a fixed antenna by far-field telemetry.
Data Source
AI summary
A procedure for measuring a measured variable in a process step of a manufacturing process uses a measurement chain with an evaluation unit and a plurality of measurement units having a sensor, a converter unit and a secondary antenna. The evaluation unit has a primary antenna. A measurement unit is positioned for measuring the measured variable and automatically coupled to the evaluation unit by establishing a transmission connection between the secondary antenna and the primary antenna. The sensor automatically generates measurement signals indicative of the measured variable. The converter unit automatically converts the measurement signals into measurement data, which the secondary antenna automatically transmits to the primary antenna.