Capacitor Sensor Array for Remote Air Gap Measurement
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Solution Overview
Problem
Existing systems face difficulties in accurately measuring and transmitting air gap distances between closely aligned mechanical components, requiring substantial manual labor and often failing to enable electrical transmission of measurements to production tools.
Innovation Solution
A system comprising a flexible substrate with a capacitor sensor array, a transmit antenna, and a microprocessor that selectively activates capacitor sensors to measure air gap distances and transmit these measurements wirelessly to a receive subsystem, facilitating remote sensing and automated production of shims.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If mechanical gauges are used to measure gap distances, then gap measurements can be obtained, but substantial manual labor is required for placement and collection of measurements
Solution Approach 1:
The patent replaces mechanical gauges with a capacitive sensing system that uses electrical fields to measure gap distances. The capacitive sensor array detects changes in capacitance caused by variations in gap distance, eliminating the need for mechanical contact and manual placement of measurement devices.
Solution Approach 2:
The capacitive sensor array automatically measures multiple gap distances across the assembly without requiring manual intervention for placement or data collection. The system self-calibrates and continuously monitors gap variations, providing automated measurement and tracking capabilities.
2Measurement precision
If traditional measurement systems are used, then gap distances can be measured, but electrical transmission of measurements to production tools is not permitted
Solution Approach 1:
The capacitive measurement system serves multiple functions: it measures gap distances, transmits data electronically to CNC production tools, and integrates with automated manufacturing processes. This multi-functional capability eliminates the need for separate measurement and manufacturing systems.
Solution Approach 2:
The patent introduces an intermediary electronic communication system that bridges the measurement device and production tools. Data from the capacitive sensors is transmitted through electronic interfaces to CNC machines, enabling automated control without direct mechanical connection.
3Measurement precision
If measurement devices are placed between closely aligned parts, then gap measurements can be obtained, but the process becomes difficult or impossible when parts are very closely aligned
Solution Approach 1:
The capacitive sensing system uses electrical fields that can penetrate and detect gap distances without requiring physical insertion of measurement devices. This allows measurement of extremely small gaps that would be inaccessible to mechanical gauges.
Solution Approach 2:
The patent transitions from one-dimensional point measurements to two-dimensional array measurements. The capacitive sensor array provides spatial distribution of gap measurements across the assembly surface, enabling detection of localized variations that point measurements would miss.
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
Enables precise, remote measurement of air gaps with reduced manual labor, allowing for the construction of detailed gap profiles and automated manufacturing of shims to fill these gaps, even between closely aligned components.
Implementation Method 1
a capacitor sensor array attached to the substrate and including a plurality of capacitor sensors... determining, by the microprocessor, a gap distance between the selected capacitor sensor and a conductive ground plane
Data Source
AI summary
A system for remote sensing of air gaps includes a substrate and a capacitor sensor array attached to the substrate, where the capacitor sensor array includes a plurality of capacitor sensors. The system also includes a transmit antenna attached to the substrate, and a microprocessor electrically connected to the transmit antenna and the capacitor sensor array. The microprocessor is configured to switch on and off at least one capacitor sensor of the plurality of capacitor sensors and to transmit determined air gap measurements using the transmit antenna.