Clone Coil Sensor Arrangement for Remote Rotational Speed Verification
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Solution Overview
Problem
Existing sensor arrangements for monitoring rotational speeds of shafts struggle to accurately determine correct operation at desired deviation levels, leading to potential system malfunctions and safety risks, as they often require bench testing and may not ensure proper recalibration during reinstallation.
Innovation Solution
A sensor arrangement utilizing a clone coil between the target and sensor, which operates in two modes: an interrogatory mode to determine base speed and an injection mode to emulate pulses, allowing for remote testing and calibration of sensor operation without disrupting normal target-sensor interactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal plate is inserted between sensor and target to block sensor effects for testing, then the sensor arrangement can be partially tested, but it cannot determine correct operation at actual desired trigger deviation levels and requires bench testing with plant downtime
Solution Approach 1:
A clone coil is introduced as an intermediary component positioned between the target and the sensor. This clone coil receives electromagnetic pulses from the sensor and re-transmits them, allowing the sensor to be tested without physically blocking the target-sensor interaction. The clone coil acts as a mediator that enables remote testing while maintaining normal operational conditions, eliminating the need for plant downtime.
Solution Approach 2:
The clone coil creates a copy of the electromagnetic pulse signal that would normally be generated by the target-sensor interaction. By positioning the clone coil to receive and re-transmit these pulses, it simulates the presence of the target without requiring physical blocking. This copying mechanism allows for accurate testing of trigger deviation levels while the system remains operational.
2Measurement precision
If bench testing is performed to verify sensor calibration, then recalibration can be confirmed, but it causes plant downtime and raises concerns about correct re-installation calibration
Solution Approach 1:
The clone coil is pre-positioned between the target and sensor during installation, ready for future testing operations. This preliminary setup allows the sensor to be tested and calibrated in-situ without requiring removal or bench testing. The clone coil remains in place during normal operation and can be activated for testing at any time, eliminating the need for plant downtime while ensuring calibration accuracy.
3Measurement precision
If the clone coil is in open circuit configuration, then it is transparent to target-sensor interaction and allows base pulse detection, but cannot emulate pulses for testing
Solution Approach 1:
The clone coil is designed with dynamic reconfigurability, allowing it to switch between open circuit and closed circuit configurations. In the open circuit mode, it remains transparent to the target-sensor interaction, enabling accurate base speed determination. When switched to closed circuit mode, it can emulate pulses for testing. This dynamic adaptability allows the same component to serve multiple functions without compromising measurement precision.
4Reliability
If the clone coil is in closed circuit configuration, then it can transmit emulating pulses to the sensor for testing, but masks the actual target-sensor interaction
Solution Approach 1:
The clone coil operates in periodic cycles, alternating between open circuit mode for accurate base speed determination and closed circuit mode for emulating pulses during testing. This periodic switching ensures that actual speed data is captured during open circuit phases, while testing can be performed during closed circuit phases. The systematic alternation between modes prevents permanent loss of information while enabling comprehensive testing.
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 reliable and remote testing of sensor arrangements to ensure correct operation at predefined deviation levels, reducing downtime and ensuring accurate triggering of alarms and shutdowns, thus enhancing safety and operational efficiency.
Implementation Method 1
a first clone coil configuration in an interrogatory mode provides base pulses to a processor
Implementation Method 2
a second clone coil configuration in an injection mode provides emulating pulses in use to a sensor
Data Source
AI summary
A sensor arrangement and method for an inductively rotational sensor consisting of a remote clone coil connected to a processor. The clone coil is located between a proximity sensor including a sensor and a rotating target so that when in an input or interrogatory mode rotational speed of the targets on a rotatable body is detected by the clone coil as a base rotational speed. The processor and the clone coil in an injection or output mode presenting emulating pulses to the sensor to mask the normal sensor coil to target interaction so the sensor coil sees the emulating pulses as the indicator of rotational speed. The emulating pulses proportional to the base speed and adjustable to desired levels of variation from the base speed as a reference.