Cable-Free Sensor Head for Early Fatigue Detection
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Solution Overview
Problem
Existing sensor systems for detecting mechanical changes in amusement rides require a power source, leading to complexity, high costs, and increased weight, which complicates their integration and effectiveness, especially in moving vehicles.
Innovation Solution
A sensor system with a sensor head featuring a brittle ampoule and measuring conductor that detects mechanical changes by altering electrical resistance, allowing for power-free operation and redundant detection methods, including optical and olfactory markers, to enhance safety without cables or external voltage sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensor systems are connected to voltage sources and monitoring circuits via cables, then detection reliability is improved, but device complexity and weight increase
Solution Approach 1:
The sensor system is divided into a sensor head containing the measurement conductor and a separate sensor housing with electronics. This modular segmentation allows the measurement conductor to be simple and lightweight while the electronics are contained in a separate housing, reducing overall device complexity without compromising detection reliability.
Solution Approach 2:
A cableless communication interface serves as an intermediary between the sensor head and monitoring circuits. This intermediary enables data transmission without physical cable connections, eliminating the complexity and weight associated with cable-based connections while maintaining reliable detection capabilities.
2Reliability
If sensor systems carry voltage sources, then proper functioning is ensured, but weight and device complexity increase
Solution Approach 1:
The sensor head is designed to function without carrying its own voltage source. The measurement conductor generates detectable signals through mechanical deformation alone, and the sensor housing contains the necessary electronics to process these signals. This self-service approach eliminates the need for heavy battery packs or power supplies in the moving sensor components.
Solution Approach 2:
The patent replaces the mechanical/electrical system of carrying voltage sources and cables with a cableless communication system. The measurement conductor's mechanical deformation directly modulates an electromagnetic field or optical signal, substituting heavy electrical power systems with lightweight field-based communication.
3Reliability
If sensors are integrated into moving vehicles and cabins, then safety monitoring is improved, but installation complexity increases due to cable routing
Solution Approach 1:
The cable connections are extracted from the sensor head and relocated to the sensor housing. This extraction simplifies the installation process in moving vehicles, as the sensor head can be mounted without complex cable routing, while the housing with electronics can be positioned separately and connected via simple interfaces.
Solution Approach 2:
The sensor system is designed with universal mounting capabilities that work across different amusement ride configurations. The cableless architecture provides a universal solution that eliminates the need for custom cable routing in each installation, making the system easily adaptable to various vehicle and cabin designs.
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 system effectively detects mechanical changes, such as fatigue and wear, in various materials, reducing incorrect detections and enhancing safety with modular, wireless, and cable-free operation, suitable for diverse amusement ride components.
Implementation Method 1
the electrical resistance of the measuring conductor changes or the electrical conductivity of the measuring conductor is destroyed, as a result of which the mechanical change in the component to be monitored can be detected by an electrical signal
Data Source
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AI summary
The present invention relates to a sensor system (1) for detecting mechanical changes, in particular material fatigue and wear and tear, at an early stage, comprising a sensor housing (2) having a receiving region (21) and a sensor head (4), wherein the sensor head (4) is maintained on the receiving region on the sensor housing (2) and is at a distance, at least in regions from the sensor housing (2). The sensor head (4) comprises a breaking body (40) having at least one measuring conductor (50). The at least one measuring conductor (50) is electrically connected by means of at least one electronic measurement unit (25) in the sensor housing (2), and the electrical resistance of the at least one measuring conductor (50) can be detected by the electronic measurement unit (25).