Coated Component Sensing via Single-Channel Frequency Separation

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Solution Overview

Problem

Existing systems for sensing the condition of coated structures face challenges in accurately combining signals from multiple sensors due to varying communication channel conditions, leading to potential false indications and increased energy consumption, while also compromising the protective qualities of the coating.

Innovation Solution

A system and method that utilizes a single communication channel to combine signals from sensors embedded in the coating and external sensors, allowing for precise signal integration and reduced energy consumption by using separate frequency domains for each sensor type, thereby maintaining the coating's protective qualities.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If multiple sensors are used to improve condition prediction accuracy, then measurement precision is improved, but device complexity increases

Engineering Contradiction:

Improvecondition prediction accuracyVSAvoidsignal management complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent combines multiple sensor signals (EIS, temperature, humidity) into a unified communication channel, integrating them into a single data stream that is processed together, thereby reducing the complexity of managing separate signal paths while maintaining the benefits of multiple sensors

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The communication channel is designed to handle multiple types of sensor signals simultaneously, serving as a universal interface that accommodates different sensor types (electrochemical, environmental) without requiring separate dedicated channels for each

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If signals are communicated through separate channels, then signal communication reliability is improved, but energy consumption increases

Engineering Contradiction:

Improvesignal communication reliabilityVSAvoidenergy consumption

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

Multiple sensor signals are merged into a single communication channel, reducing the total number of active communication paths and thereby lowering energy consumption while maintaining reliable signal transmission through unified channel management

Inventive Principle:

Principle #5Merging (Combining)

3Measurement precision

If wired sensors are embedded between coating layers, then measurement precision is improved, but the coating's protective quality deteriorates

Engineering Contradiction:

Improvecoating condition detection accuracyVSAvoidcoating protective quality

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The patent uses the coating layers themselves as intermediaries to conduct sensor signals, allowing electrical connections to be made through the coating structure without creating penetrating wires that would compromise the coating's barrier properties against air and water ingress

Inventive Principle:

Principle #24Intermediary (Mediator)

4Reliability

If multiple communication channels are used, then signal communication reliability is improved, but device complexity increases

Engineering Contradiction:

Improvesignal communication reliabilityVSAvoidcommunication channel management

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges multiple sensor signals into a single communication channel, simplifying the communication architecture while maintaining reliability through unified signal processing and centralized channel management

Inventive Principle:

Principle #5Merging (Combining)

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

This approach enhances the accuracy of condition assessments by ensuring consistent signal communication conditions and reduces energy consumption, while simplifying system assembly and data acquisition, enabling efficient and precise monitoring of coated structures.

Implementation Method 1

at least one first sensor configured to convert a first physical property into a first electrical signal

Methodology Applied

Scientific EffectTemperature sensing: Thermistor

Implementation Method 2

at least one second sensor configured to convert a second physical property into a second electrical signal

Methodology Applied

Scientific EffectHumidity sensing: Capacitance

Implementation Method 3

at least one additional sensor comprising at least one electrode embedded in the coating and configured to provide at least one additional signal

Methodology Applied

Scientific EffectElectrical impedance sensing: Electrical Impedance Tomography

Implementation Method 4

The first electrical signal is communicated in a first frequency domain of the first communication channel and the second electrical signal is communicated in a second frequency domain of the first communication channel

Methodology Applied

Scientific EffectFrequency domain separation:

Data Source

PatentUS20250377287A1A system and a method for sensing a condition of a component

Publication Date: 2025.12.11 HEMPEL AS

AI summary

A system for sensing a condition of a component comprising a structure covered by a coating. A first electrical signal and a second electrical signal are communicated to a computer system via a single communication channel, and in the computer system, the signals are separated and subsequently used in combination to provide an indication of the condition of the component or a humidity.