Wireless Node Internal Force Sensor Sealing
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Solution Overview
Problem
The high costs associated with transmitting data from remote industrial equipment locations, where cellular and satellite infrastructure is limited or absent, make it economically prohibitive for industrial operations to deploy wireless sensor networks for data collection and processing, leading to inefficient data collection and potential errors when relying on manual human visits for data acquisition.
Innovation Solution
The implementation of a 'walk-in device' that automatically establishes communication with industrial equipment using Bluetooth, WiFi, or Zigbee, collects data, and performs maintenance tasks, such as software updates and calibration, while also utilizing internal force sensors to initiate operations without external buttons, thereby reducing the need for costly infrastructure and minimizing human error.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If wireless sensor networks are deployed to collect data from remote industrial equipment, then data collection efficiency is improved, but transmission costs become prohibitive due to lack of cellular infrastructure
Solution Approach 1:
The patent introduces a local server as an intermediary device deployed at remote industrial locations. This server acts as a mediator between industrial equipment and external networks, enabling data collection and processing locally without requiring direct cellular connectivity to remote equipment. The server can store, pre-process, and manage data locally, reducing the need for expensive dedicated transmission infrastructure to every remote point.
Solution Approach 2:
The local server enables industrial equipment to serve itself by providing data collection, storage, and processing capabilities directly at the remote location. The server can autonomously manage data from multiple equipment pieces, perform local analytics, and only transmit aggregated or critical data when connectivity is available, reducing ongoing transmission costs while maintaining data collection efficiency.
2Loss of energy
If manual human visits are used for data acquisition from remote equipment, then infrastructure costs are reduced, but errors increase due to human involvement
Solution Approach 1:
The local server automatically collects, stores, and processes data from industrial equipment without requiring manual human intervention. This automated system eliminates human errors in data recording and transmission while maintaining low infrastructure costs. The server can continuously monitor equipment and upload data when connectivity is available, ensuring both accuracy and cost-effectiveness.
Solution Approach 2:
The system implements automated feedback mechanisms where the local server continuously monitors equipment status, validates data integrity, and automatically transmits data when connectivity is available. This closed-loop system ensures data accuracy through automated validation and error checking, eliminating the need for manual verification while maintaining reliability.
3Ease of operation
If external buttons are added to the node for user interaction, then ease of operation is improved, but susceptibility to fluid intrusion increases
Solution Approach 1:
The patent replaces mechanical external buttons with an internal force sensor system that detects user input through non-contact or sealed contact mechanisms. The force sensor is positioned inside the sealed housing and detects pressure or force applied to the housing exterior, translating mechanical input into electrical signals without requiring external openings. This substitution eliminates the need for button openings while maintaining full user interaction capability.
Solution Approach 2:
The housing structure itself acts as an intermediary between user input and the internal force sensor. Force or pressure applied to the housing exterior is transmitted through the sealed housing walls to the internal force sensor, which converts this mechanical input into electrical signals. This intermediary mechanism allows user interaction while keeping the housing sealed against fluid intrusion.
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 reduces operational expenses by eliminating the need for extensive communication networks and minimizes errors through automated data collection and maintenance, allowing for efficient and secure data transfer directly to authorized devices, enhancing the reliability and cost-effectiveness of industrial data management.
Implementation Method 1
a deflection detector on the base plate within the housing, the deflection detector configured to provide an input to the node control circuitry in response to a user-provided force being applied to the housing
Data Source
AI summary
A wireless instrument area network node employs an internal force sensor arrangement to detect user-provided force on the node and initiate a node operation, such as wake the node from a sleep state or low power mode to a more power-hungry awake and processing state. The internal force sensor avoids the need to provide external buttons, a screen, and the like on the surface of the node that could lead to intrusion of fluids, gases, or other unwanted substances into the node. In some embodiments, the internal sensor may include a microswitch that has sufficient sensitivity to detect even a very small amount of deflection resulting from, for example, a hand touch. In some embodiments, the internal sensor may include a piezoelectric sensor that has similarly high deflection sensitivity. Multiple such deflection detectors may be at different angles to one another deployed to provide greater directional coverage for the deflection.