Compact Wireless Sensor Assembly for Low-Power Harsh Mounting

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Solution Overview

Problem

Conventional sensor assemblies face challenges with power consumption, particularly during start-up, which can lead to energy drainage and failure in energy harvesting applications, and are difficult to use in harsh environments due to the need for external power sources and complex mounting structures.

Innovation Solution

A wireless sensor assembly with a housing containing a wireless power source and electronics that include a communication board and sensor connector, allowing data transmission while minimizing power consumption and enabling secure mounting in harsh environments through angled sealing interfaces and detachable portions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If an integrated battery is used as power source, then the sensor can operate independently, but the sensor size increases and cannot be made small

Engineering Contradiction:

Improveindependent operationVSAvoidsensor size

Core Design Contradiction:

Ease of operationVSVolume of moving object

Solution Approach 1:

The patent extracts the battery from the sensor assembly, separating the power source from the sensing unit. The sensor operates independently during measurement but connects to external power during data processing, eliminating the need for an integrated battery while maintaining independent operation capability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The system is divided into two functional segments: a compact sensor unit for data acquisition and an external processing unit for data analysis. This segmentation allows the sensor to be small while the battery resides in the separate processing unit.

Inventive Principle:

Principle #1Segmentation

2Use of energy by moving object

If the sensor is connected to external power source by wires, then power consumption is managed, but it is difficult to use in harsh environment or mount to complicated structure

Engineering Contradiction:

Improvepower consumption managementVSAvoidusability in harsh environment

Core Design Contradiction:

Use of energy by moving objectVSEase of operation

Solution Approach 1:

The patent replaces the mechanical wire connection with a wireless communication system. Data is transmitted wirelessly from the sensor to the processing unit, eliminating the need for physical wire connections while maintaining power management capabilities.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Use of energy by moving object

If low-power microprocessors are used, then power consumption during operation is reduced, but initial power consumption at start-up is high causing energy drainage

Engineering Contradiction:

Improveoperational power consumptionVSAvoidstart-up energy drainage

Core Design Contradiction:

Use of energy by moving objectVSLoss of energy

Solution Approach 1:

The system performs preliminary actions by pre-processing data on the sensor before transmission. This reduces the computational burden and power consumption during start-up of the external microprocessor, as much of the data processing is already completed by the time data is received.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The sensor performs partial data processing locally using minimal power, and the external system performs the remaining processing. This division allows the low-power microprocessor to handle only essential functions while the more powerful external processor handles intensive computations.

Inventive Principle:

Principle #16Partial or excessive action

4Extent of automation

If processing unit is integrated with sensor, then data processing is performed locally, but the sensor cannot be made small

Engineering Contradiction:

Improvelocal data processingVSAvoidsensor size

Core Design Contradiction:

Extent of automationVSVolume of moving object

Solution Approach 1:

The processing unit is extracted from the sensor assembly and placed in a separate external device. The sensor retains only the essential sensing functions, making it compact, while the processing unit handles all data analysis tasks externally.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The system is segmented into a minimal sensor unit for data acquisition and a separate processing unit for data analysis. This segmentation enables the sensor to be made small while maintaining local processing capability through wireless data transmission.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS11825250B2Compact modular wireless sensor

Publication Date: 2023.11.21 WATLOW ELECTRIC MANUFACTURING CO

AI summary

A sensor assembly includes a housing that defines an interior space. The sensor assembly includes a sensor connected to the housing at the aperture. The sensor assembly includes a wireless power source disposed within the interior space. The sensor assembly includes electronics disposed within the interior space and configured to receive power from the wireless power source. The electronics include a communication board and a sensor connector, and the sensor is configured to transmit data to the communication board via the sensor connector.