Wireless Measuring Chain for Fast Tool-Change Data Coupling
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Solution Overview
Problem
Existing manufacturing processes face challenges in quickly re-establishing measurement chains during process steps, leading to interruptions and increased costs due to the need for frequent sensor and coil replacements, and the limitations of strain gauges in achieving high dynamic measurement resolution.
Innovation Solution
A method utilizing a measuring chain with multiple measuring units, each equipped with a sensor, transducer unit, and secondary antenna, automatically coupling with an evaluation unit via a primary antenna to establish a transmission connection, allowing for rapid re-establishment of measurement data transmission and high dynamic measurement resolution without the need for frequent replacements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor device with stationary coil is used for measurement, then measurement accuracy is improved, but the measuring chain must be interrupted and re-established during tool replacement
Solution Approach 1:
The evaluation unit is designed to universally accept measurement data from multiple different sensor devices through wireless communication. The system can switch between different sensor devices assigned to different tools without requiring physical reconnection, allowing the same evaluation unit to serve multiple measurement scenarios across various process steps.
Solution Approach 2:
The patent replaces the mechanical connection system (signal lines physically connecting sensor to evaluation unit) with a wireless communication system. Measurement data is transmitted via wireless signals between the sensor device and evaluation unit, eliminating the need for physical plug-and-play connections during tool replacement, thus reducing interruption time while maintaining measurement accuracy.
2Ease of manufacture
If strain gauge is used as sensor, then cost is reduced, but dynamic measurement resolution is limited
Solution Approach 1:
The patent changes the measurement parameters by using piezoelectric sensors instead of strain gauges. Piezoelectric sensors can measure dynamic variables at high frequencies (up to 35kHz) due to their inherent electrical charge generation mechanism under mechanical stress, providing superior dynamic measurement resolution while remaining cost-effective for precision machining applications.
3Measurement precision
If sensor device is replaced with each tool, then measurement accuracy is maintained, but device complexity and cost increase
Solution Approach 1:
The evaluation unit is designed to universally accept measurement data from multiple different sensor devices through wireless communication. The system can switch between different sensor devices assigned to different tools without requiring physical reconnection, allowing the same evaluation unit to serve multiple measurement scenarios across various process steps.
Solution Approach 2:
Instead of having dedicated hardware connections for each tool-sensor pair, the system creates a virtual copy of the measurement connection through wireless communication protocols. The evaluation unit receives and processes measurement data from multiple sensor devices as if they were directly connected, reducing the need for multiple physical connection sets while maintaining measurement integrity.
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 approach enables quick re-establishment of measurement chains, reducing latency and costs, while achieving high accuracy and dynamic measurement resolution, even during rapid process steps and tool changes.
Implementation Method 1
The secondary antenna sends the measurement data automatically to the primary antenna using far-field telemetry
Data Source
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AI summary
The invention relates to a method for measuring a measured quantity (MQ) during a process step of a manufacturing process, using a measuring chain (1) with several measuring units (10, 10', 10'') and an evaluation unit (20); wherein each of the measuring units (10, 10', 10'') comprises a sensor (11, 11', 11''), a transducer unit (12, 12', 12'') and a secondary antenna (13, 13', 13''); wherein the evaluation unit (20) comprises a primary antenna (23); and wherein in each of the process steps the following procedure steps are carried out: Positioning (I) one of the several measuring units (10, 10', 10") in a measuring position (15) for measuring the measured quantity (MG); automatic coupling (II) of the positioned measuring unit (10, 10', 10'') by establishing a transmit connection between the secondary antenna (13, 13', 13'') and the primary antenna (23) with the evaluation unit (20);Automatic generation (III) of measurement signals (MS) under the influence of the measured quantity (MG) by the sensor (11, 11', 11") of the positioned measuring unit (10, 10', 10"); automatic conversion (IV) of the measurement signals (MS) by the converter unit (12, 12', 12") of the positioned measuring unit (10, 10', 10") into measurement data (MD); and automatic transmission (V) of the measurement data (MD) by the secondary antenna (13, 13', 13") of the positioned measuring unit (10, 10', 10") to the primary antenna (23).;