Air-Core Inductor Temperature Sensing Without Wired Power
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Solution Overview
Problem
Monitoring and maintaining high-voltage air choke coils poses challenges due to their high electrical potential, requiring reliable and maintenance-free temperature detection and data transmission solutions that avoid the limitations of wired or fiber optic power supplies and battery replacement efforts.
Innovation Solution
A thermographic sensor and contactless data transmission system utilizing energy harvesting from the electromagnetic field of the air choke coil, combined with a digital twin for data integration and analysis, enables reliable temperature measurement and prediction of remaining service life without the need for batteries or wired connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fiber optic cables are used for power supply and communication with sensors, then galvanic isolation between sensor system wiring and high-voltage components is improved, but device complexity and manufacturing costs increase due to additional measures for creepage distances and contamination protection
Solution Approach 1:
The patent extracts the power supply function from the sensor system by using energy harvesting from the electromagnetic field, completely eliminating the need for fiber optic power supply cables and their associated isolation measures, thus reducing device complexity while maintaining galvanic isolation
Solution Approach 2:
The patent introduces an intermediary energy harvesting device that converts electromagnetic field energy into electrical energy to power the sensor, replacing the direct fiber optic power supply connection and simplifying the overall system architecture
2Ease of operation
If wireless sensors with long-life batteries are used, then maintenance effort is reduced compared to frequent battery replacement, but reliability deteriorates in high-temperature environments where batteries are impossible or only feasible with frequent replacement
Solution Approach 1:
The sensor system serves itself by harvesting energy directly from the electromagnetic field generated by the high-voltage component, eliminating the need for external batteries and their associated maintenance and replacement issues in high-temperature environments
Solution Approach 2:
The patent changes the energy source parameter from chemical energy (batteries) to electromagnetic energy, enabling reliable operation in high-temperature environments where batteries fail, while maintaining low maintenance requirements
3Ease of operation
If periodic maintenance intervals are used, then operational simplicity is maintained, but productivity decreases due to inability to detect potential failures early and shift to condition-based maintenance
Solution Approach 1:
The patent implements continuous temperature monitoring with feedback to the cloud platform, enabling real-time assessment of component condition and transition from periodic to condition-based maintenance, thereby optimizing service life and detecting potential failures early
Solution Approach 2:
The system performs preliminary detection of aging processes and potential failures through continuous monitoring and simulation methods, allowing proactive maintenance planning before actual failures occur, thus improving productivity and reducing unplanned interruptions
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 provides continuous, maintenance-free monitoring and prediction of air choke coil service life, reducing unplanned interruptions and enabling condition-based maintenance through accurate temperature measurement and data-driven insights.
Implementation Method 1
powered from the coil's electromagnetic field using 'energy harvesting' methods
Implementation Method 2
A thermographic sensor and means for contactless data transmission are attached to an air-core choke coil
Data Source
Figure 1
AI summary
The invention relates to an air-core inductor with a temperature measuring system, wherein a thermographic sensor, means for generating electrical energy from the electromagnetic field and means for contactless data transmission are arranged on the air-core inductor (1).