Built-in Electrode ECT Sensor for High-Temperature Imaging
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Solution Overview
Problem
Developing a high-temperature resistant built-in electrode electrical capacitance tomography (ECT) sensor is challenging due to the need for materials that are both conductive and insulating, with no existing signal transmission cables suitable for high-temperature environments, and requiring precise electrode placement and interference-free signal transmission.
Innovation Solution
A barrel-shaped ECT sensor design featuring array-distributed electrodes made from high-temperature resistant metal conductors, an insulating sleeve, a flange outer tube, and a signal transmission line with a high-temperature section and normal temperature section, using shielding wire meshes to ensure reliable signal transmission up to 1000°C.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional external electrode ECT sensor is used, then the sensor can be manufactured with simple structure, but it cannot withstand high temperature environments (up to 600°C limitation)
Solution Approach 1:
The sensor is divided into distinct functional modules: high-temperature resistant electrode sheets, insulating sleeves, shielding layers, and signal transmission cables. Each component is independently optimized for high-temperature performance, allowing the overall system to withstand temperatures up to 1000°C while maintaining manageable complexity through modular assembly
Solution Approach 2:
The patent employs composite material structures including metal electrode sheets combined with ceramic or high-temperature polymer insulating sleeves, and composite shielding layers. These composite constructions provide both mechanical support and electrical insulation properties necessary for high-temperature operation, resolving the contradiction between temperature resistance and structural complexity
2Temperature
If built-in electrode design is adopted for high temperature resistance, then temperature resistance is improved, but the manufacturing process becomes more complicated
Solution Approach 1:
Electrode sheets are pre-cut and pre-positioned with precise dimensions and arrangements before assembly. Insulating sleeves are pre-fitted onto electrode supports, and shielding layers are pre-assembled. This preliminary preparation simplifies the final assembly process and ensures manufacturing precision without requiring complex in-situ fabrication at high temperatures
Solution Approach 2:
High-temperature resistant adhesive materials and mechanical fastening structures serve as intermediaries to securely attach electrode sheets to the sensor body and fix signal cables in place. These intermediary components enable reliable bonding and fixation that can withstand high-temperature environments while simplifying the overall manufacturing process through standardized connection methods
3Measurement precision
If electrode sheets are closely attached to container wall for accurate measurement, then measurement precision is improved, but electrode positioning accuracy becomes more difficult to control
Solution Approach 1:
Insulating sleeves with precisely controlled inner diameters serve as intermediary components between the electrode sheets and the container wall. These sleeves provide a standardized interface that ensures uniform spacing and accurate positioning of electrodes, thereby maintaining measurement precision while simplifying the positioning process during manufacturing
Solution Approach 2:
Thin insulating layers and flexible mounting structures are used to accommodate minor variations in container wall geometry while maintaining consistent electrode positioning. These flexible elements allow the electrode assembly to adapt to slight dimensional tolerances without compromising measurement accuracy or requiring extremely tight manufacturing controls
4Reliability
If weak electrical signals are transmitted from high temperature zone, then signal transmission is achieved, but signal interference increases
Solution Approach 1:
Multiple shielding layers including metallic mesh shields and grounded conducting shields are positioned between the high-temperature measurement zone and the signal acquisition electronics. These intermediary shielding structures block electromagnetic interference and thermal noise from contaminating the weak capacitance signals, thereby improving signal transmission reliability without requiring the signals to travel directly through the high-temperature environment
Solution Approach 2:
The signal transmission path is segmented into distinct zones: a high-temperature measurement zone with electrodes, an intermediate shielding zone with multiple protective layers, and a low-temperature signal processing zone. This spatial segmentation isolates the vulnerable weak signals from harmful interference sources while maintaining transmission reliability through controlled signal paths
5Temperature
If high temperature resistant materials are selected for all components, then temperature resistance is improved, but material selection and processing becomes more difficult
Solution Approach 1:
Different components are assigned different levels of high-temperature resistance based on their specific functional requirements and thermal exposure conditions. Electrode sheets and insulating sleeves directly in the measurement zone use materials rated for highest temperatures, while external shielding and cable components use materials with appropriate temperature ratings for their specific locations. This localized material selection optimizes overall temperature resistance while reducing manufacturing complexity compared to using extreme high-temperature materials for all components
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
The solution enables accurate two-dimensional imaging of medium distribution in high-temperature environments, extending the application of ECT technology and ensuring the sensor's components remain functional and interference-free.
Implementation Method 1
the equivalent dielectric constant will change, which will cause the change of capacitance value between the electrode pairs measured by the sensor
Implementation Method 2
different materials have different dielectric constants
Implementation Method 3
using shielding wire meshes to ensure reliable signal transmission up to 1000°C
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A built-in electrode electrical capacitance tomography sensor, characterized in that the electrical capacitance tomography sensor is a barrel sensor, and sequentially comprises, from inside to outside, an array distribution electrode (1), an electrode insulating sleeve (2), a flange outer tube (3), an insulating tube (4) and a signal transmission line. The array distribution electrode (1) includes N electrode sheets of the same size and consists of measurement ends and fixed ends, N being an integer of 8-16. The electrode is connected to an electrical capacitance tomography signal acquisition system (13) by means of a transmission line, and the acquired electrical capacitance data is sent to the electrical capacitance tomography signal acquisition system (13) by means of a signal transmission line, and is then sent to an imaging computer by means of the electrical capacitance tomography signal acquisition system (13) so as to complete image reconstruction.