Composite Ultrasonic Waveguide Temperature Sensor for Harsh Environments
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Solution Overview
Problem
Conventional temperature sensors fail frequently in harsh environments due to material limitations, thermal expansion issues, and susceptibility to sensor drift, leading to high maintenance costs and inaccurate measurements.
Innovation Solution
A composite active mechanical waveguide temperature sensor is developed, featuring a sensor portion made of environment-resistant materials like ceramics coupled through an ultrasonically-transparent bond to a waveguide portion made of ultrasonically-transmissive materials like metallic filament wires, allowing for reliable temperature measurement in harsh conditions by propagating ultrasonic energy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional sensors are used in harsh environments, then they can measure temperature, but they fail frequently due to material limitations and thermal expansion issues
Solution Approach 1:
The sensor is divided into two distinct portions: a sensor portion made of environment-resistant material (such as ceramic) that withstands harsh conditions, and a waveguide portion made of ultrasonically-transmissive material (such as metallic filament wire) that transmits ultrasonic signals. This segmentation allows each portion to be optimized for its specific function, resolving the contradiction between reliability in harsh environments and material strength limitations.
Solution Approach 2:
The invention uses a composite structure combining different materials with complementary properties: the sensor portion uses environment-resistant materials like ceramic to withstand high temperatures and harsh conditions, while the waveguide portion uses materials optimized for ultrasonic transmission. This composite approach allows the sensor to operate reliably in harsh environments without compromising material strength.
2Measurement precision
If conventional sensors are used in harsh environments, then they can measure temperature, but they are susceptible to sensor drift leading to inaccurate measurements
Solution Approach 1:
The invention replaces conventional electrical sensing mechanisms with ultrasonic wave propagation through the waveguide portion. By measuring the transmission characteristics of ultrasonic waves through the metallic filament wire, the system achieves temperature measurement without the sensor drift issues that plague conventional electrical sensors in harsh environments.
3Adaptability or versatility
If dissimilar materials are bonded together in conventional sensors, then different functions can be integrated, but varying thermal expansion rates introduce mechanical strains and increase failure rates
Solution Approach 1:
Each portion of the composite sensor is designed with local quality optimized for its specific function: the sensor portion uses environment-resistant material properties to withstand harsh conditions, while the waveguide portion uses ultrasonically-transmissive material properties for signal transmission. This localized optimization reduces the impact of thermal expansion mismatches compared to conventional multi-material sensors.
4Measurement precision
If ultrasonic energy is propagated through wires in harsh environments, then temperature can be measured, but signal attenuation and noise reduce measurement accuracy
Solution Approach 1:
The invention optimizes the physical parameters of the waveguide portion, specifically using metallic filament wire with diameter less than 0.125 inches, which provides favorable ultrasonic transmission characteristics. By carefully selecting and optimizing these parameters, the system minimizes signal attenuation and noise while maintaining the ability to measure temperature accurately in harsh environments.
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 composite sensor effectively measures temperature in harsh environments with reduced signal attenuation and noise, providing accurate and durable performance even in extreme conditions such as high-temperature combustion chambers.
Implementation Method 1
an ultrasonic transducer coupled directly to the mating end of the sensor portion through an ultrasonically-transparent bond
Implementation Method 2
coupled through an ultrasonically-transparent bond to a waveguide portion formed of an ultrasonically-transmissive material
Data Source
AI summary
A composite active waveguide temperature sensor (10) incorporates a first, sensor portion (16) formed of an environment-resistant material such as ceramic coupled through an ultrasonically-transparent bond (20) to a second, waveguide portion (18) formed of an ultrasonically-transmissive material such as a metallic filament wire. By doing so, the sensor portion (16) may be positioned within a harsh environment and subjected to a temperature to be measured, and the waveguide portion (18) may be used to propagate ultrasonic energy to and/or from the sensor portion (16) to a location distal from the harsh environment for measurement of the temperature. The ultrasonically-transparent bond (20) between these portions (16, 18) limits attenuation of and the introduction of reflections and other noise to an ultrasonic signal propagated across the bond (20).