3D Conformal Sensor Coil for Non-Planar Surface Inspection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing sensor manufacturing methods for detecting defects or monitoring fluids in industrial pipelines are limited by long lead times, economic inefficiencies, and the inability to produce non-planar sensor coils, which restricts their application and scalability.
Innovation Solution
The use of additive manufacturing techniques, such as 3D metal printing or laser sintering, allows for the creation of complex-shaped sensor coils that match the cross-sectional profile of objects being inspected, enabling the formation of unibody sensors with enhanced surface contact and reduced assembly costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional sensor manufacturing methods are used, then manufacturing process is simple and cost-effective, but manufacturing lead time is long and production efficiency is low
Solution Approach 1:
The patent combines multiple manufacturing steps (substrate preparation, coil winding, insulation application, and sealing) into a single integrated additive manufacturing process. The sensor coil is printed directly onto the substrate in one continuous operation, eliminating the need for separate assembly steps and significantly reducing manufacturing lead time while maintaining cost-effectiveness.
Solution Approach 2:
The patent changes the manufacturing approach from traditional planar PCB methods to three-dimensional additive manufacturing. This parameter change enables complex non-planar sensor coil geometries to be created directly, improving productivity by eliminating multiple assembly operations while the digital modeling aspect maintains ease of manufacture through software-controlled processes.
2Measurement precision
If planar sensor coils are used, then manufacturing is easier and costs are lower, but sensor sensitivity and accuracy are reduced due to limited contact area with non-planar objects
Solution Approach 1:
The patent employs three-dimensional curved and non-planar sensor coil geometries that conform to the surface of the object being inspected. This curvature enables maximum contact area between the sensor coil and non-planar surfaces such as pipes, significantly improving measurement precision and sensor sensitivity compared to traditional flat coils.
Solution Approach 2:
The patent transitions from two-dimensional planar sensor coils to three-dimensional volumetric sensor structures. By adding the vertical dimension through additive manufacturing, the sensor can wrap around and conform to cylindrical and irregular surfaces, dramatically increasing contact area and measurement accuracy while the digital design process keeps device complexity manageable.
3Manufacturing precision
If complex-shaped sensor coils are manufactured using traditional methods, then manufacturing precision can be achieved, but device complexity increases and assembly costs rise
Solution Approach 1:
The patent merges multiple previously separate components (substrate, insulation layers, coil windings, and sealing elements) into a single integrated structure created through additive manufacturing. This consolidation maintains manufacturing precision for complex shapes while eliminating the need for separate assembly operations, thereby reducing device complexity and assembly costs.
Solution Approach 2:
The patent uses digital 3D modeling to pre-plan and optimize the sensor coil geometry before manufacturing. This preliminary digital action allows complex shapes to be precisely designed and simulated, ensuring manufacturing precision is achieved while the digital workflow simplifies the overall device complexity by eliminating physical trial-and-error prototyping and assembly iterations.
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 increases the sensitivity and accuracy of sensors by maximizing contact with non-planar object surfaces, broadening their application and reducing manufacturing lead times and costs, while enabling rapid prototyping of new designs.
Implementation Method 1
additive manufacturing techniques, such as 3D metal printing or laser sintering
Implementation Method 2
additive manufacturing techniques, such as 3D metal printing or laser sintering
Data Source
AI summary
A method of manufacturing is provided. The method can include determining a cross-sectional shape of an object to be inspected using a sensor configured with a sensor coil. The method can also include providing a substrate having a profile matching the cross-sectional shape of the object. The method can further include applying a dielectric material to the substrate in a patter matching a shape of the sensor coil. The method can also include forming a first layer of a first material on the dielectric material by sputtering particles of the first material on the dielectric material in the pattern and forming additional layers of the first material atop the first layer by iteratively depositing the additional layers in the pattern via an additive manufacturing technique. A sensor including a sensor coil formed via the method is also provided.