Crack Sensor Segmented Planar Resistors Orthogonal Detection
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Solution Overview
Problem
Existing crack sensors for detecting cracks in constructions like bridges and tunnels are limited in their ability to effectively monitor crack extension due to the breaking force not being adequately transferred through the intermediate insulator, leading to incomplete detection of crack growth.
Innovation Solution
A crack sensor design featuring a three-layer structure with a film-shaped insulating base, a common line acting as an electronically common circuit, and gauge lead wires arranged in overlapping areas to ensure detection of crack extension even when the crack changes direction, utilizing a wiring pattern conductor and protective films to maintain signal integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an intermediate insulator is sandwiched between the second planar resistor and the insulator base, then the insulator base can be adhered on the measured object surface, but the breaking force from the insulator base cannot spread to the resistance wires of the second planar resistor
Solution Approach 1:
The patent introduces a first planar resistor as an intermediary layer between the insulator base and the second planar resistor. This intermediary structure allows the breaking force from the insulator base to be transmitted through the first planar resistor to the second planar resistor, enabling reliable crack detection while maintaining proper adhesion of the insulator base to the measured object surface.
Solution Approach 2:
The sensor is divided into multiple planar resistors (first and second planar resistors) arranged in a segmented configuration. The first planar resistor is positioned between the insulator base and the second planar resistor, creating distinct functional zones that allow force transmission while maintaining electrical measurement capabilities for crack detection.
2Adaptability or versatility
If resistance wires are arranged in a two-dimensional grid pattern, then crack extension can be detected in multiple directions, but the structure becomes complex and the breaking force transmission is insufficient
Solution Approach 1:
The sensor uses segmented planar resistors (first and second planar resistors) with resistance wires arranged in orthogonal directions. This segmentation allows detection of crack extension in multiple directions while maintaining a relatively simple overall structure compared to a fully complex two-dimensional grid, as each planar resistor handles specific directional detection.
Solution Approach 2:
The first and second planar resistors are merged into a single sensor assembly with the insulator base, creating a unified structure that provides multi-directional crack detection capability. The merging of these components achieves versatile crack detection coverage without requiring separate sensors for different directions, thus avoiding excessive complexity.
Data Source
AI summary
A crack sensor for detecting the extension of a crack comprises an insulator base material made from an insulating material, a common line formed on the insulator base material along a first direction and a plurality of gauge lead wires which is formed on the insulator base material and each of which has an end connected with the common line at an interval and another end extending in a second direction orthogonal to the first direction, wherein the extending end reaches a position to which the extending end retreats in a direction opposite to the first direction with respect to the end connected with the common line.