Corrosion Sensor Layout for Temperature-Corrected Rate Measurement
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Solution Overview
Problem
Existing corrosion rate measurement methods suffer from errors due to thermal expansion and contraction of metal sensors caused by temperature changes in the atmosphere, leading to inaccurate measurements and high inspection costs.
Innovation Solution
A corrosion rate measurement system with a corrosion sensor comprising conductive patterns for corrosion measurement and temperature correction, where the temperature correction pattern is covered and has a greater length and less surface area than the corrosion measurement pattern, allowing for accurate temperature correction and reduced measurement errors, and includes a data processing unit to calculate corrosion rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a metal electrical resistance sensor is used to measure corrosion rate, then corrosion rate can be measured, but measurement errors occur due to thermal expansion and contraction of the metal sensor caused by temperature changes
Solution Approach 1:
The sensor is divided into two separate conductive patterns: a corrosion measurement pattern exposed to the environment and a temperature correction pattern covered by a protective layer. This segmentation allows independent measurement of corrosion effects and temperature effects, enabling accurate correction of temperature-induced measurement errors.
Solution Approach 2:
The temperature correction pattern acts as an intermediary that measures only temperature effects (thermal expansion/contraction) without being affected by corrosion. Its resistance change provides a reference value that mediates the correction of the corrosion measurement pattern's resistance change, separating the two effects.
2Measurement precision
If the conductive pattern for temperature correction has greater length and less surface area, then the reference resistance measured value is greater and relative measurement error is reduced, but the device complexity increases
Solution Approach 1:
The conductive patterns are designed with different local geometries optimized for their specific functions: the temperature correction pattern has greater length and less surface area to maximize resistance value and minimize relative error, while the corrosion measurement pattern has appropriate dimensions for exposure to the environment. Each pattern's local structure is tailored to its measurement purpose.
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 system minimizes measurement errors by accurately correcting for temperature changes, enabling precise corrosion rate determination and remote monitoring through satellite communication, even in harsh environments like overseas or sea conditions, without external power sources.
Implementation Method 1
a resistance value continues to change due to thermal expansion or thermal contraction of metal due to temperature change in the atmosphere
Implementation Method 2
a conductive pattern for temperature correction of which surface is covered by a protective layer so that the conductive pattern for temperature correction is not exposed to the ambient environment on the substrate and of which thickness changes according to the ambient temperature
Data Source
AI summary
In corrosion rate measurement equipment according to an atmospheric environment according to the present invention, the length of a conductive pattern for temperature correction of a corrosion sensor is greater than the length of a conductive pattern for corrosion measurement, and the surface area of the conductive pattern for temperature correction of a corrosion sensor is less than the surface area of the conductive pattern for corrosion measurement so that a measured error of reference resistance measured values measured in the conductive pattern for temperature correction is minimized and thus the measured values measured in the conductive pattern for corrosion measurement can be more accurately corrected by using the reference resistance measured value and thus, corrosion rate can be more accurately measured.