Coaxial Clearance Sensor Structure for Thermal and Vibration Stability
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Solution Overview
Problem
Existing clearance sensors suffer from decreased long-term measurement reliability due to variations in assembly accuracy and potential wear from thermal expansion and vibrations, particularly in high-temperature environments.
Innovation Solution
A clearance sensor design featuring coaxial detection, guard, and ground electrodes with insulation members and layers, secured through screw-bonding or pin-locking, to maintain positional accuracy and reduce thermal and mechanical stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If insulation layers are attached by thermal spraying and assembly is performed with fit adjustment, then the clearance sensor can be manufactured, but assembly accuracy variation becomes great and long-term measurement reliability decreases
Solution Approach 1:
The patent replaces the mechanical assembly process (fit adjustment and thermal spraying) with a integrated structure where the insulation layer and electrode are formed as a single piece. This eliminates the need for separate attachment and assembly steps, thereby eliminating assembly accuracy variation while maintaining manufacturability through forming processes.
Solution Approach 2:
The patent merges the insulation layer and the electrode into a single integrated component. This combination eliminates the interface between separate parts, preventing assembly accuracy variation and improving long-term measurement reliability by ensuring consistent positional relationships between the detection electrode, guard electrode, and ground electrode.
2Measurement precision
If a three-layer structure with coaxial electrodes and insulation layers is used, then capacitance measurement can be performed, but assembly accuracy variation increases due to multiple components requiring fit adjustment
Solution Approach 1:
The patent combines the insulation layer and electrode into a single integrated component, eliminating the need for fit adjustment between multiple parts. This integration maintains the necessary three-layer electrode structure for capacitance measurement while eliminating assembly accuracy variation, thereby improving manufacturing precision.
3Object-generated harmful factors
If insulation layers are attached by thermal spraying, then electrical insulation is achieved, but positional deviation occurs under thermal expansion and vibrations
Solution Approach 1:
The patent integrates the insulation layer and electrode as a single component, eliminating the interface that would otherwise separate under thermal expansion and vibration. This integration ensures that the electrical insulation function is maintained while preventing positional deviation of the electrodes, as there are no separate parts to shift relative to each other.
Solution Approach 2:
The patent replaces the mechanical attachment system (thermal spraying) with an integrated structure. This substitution eliminates the vulnerability of mechanically attached insulation layers to thermal expansion and vibration, as the insulation and electrode are formed together as one piece that expands and vibrates uniformly.
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
Enhances long-term measurement reliability by suppressing positional deviation and wear, ensuring consistent performance even under high-temperature conditions.
Implementation Method 1
the insulation layers 30 are made of a viscoelastic material
Implementation Method 2
a non-contact type sensor such as a capacitance type sensor is used
Data Source
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AI summary
A clearance sensor according to the present invention comprises: a columnar detection electrode having a detection end surface on one end side in the axial direction of the center axis; an electrode member including a guard electrode and a ground electrode having the center axis coaxial with that of the detection electrode; an insulating member linking between the detection electrode and the guard electrode, and linking between the guard electrode and the ground electrode; and an insulating layer filling the spaces between the detection electrode, the guard electrode, the ground electrode, and the insulating member, wherein the space between the electrode member and the insulating member is retained in the axial direction and/or the direction around the axis of the center axis.