Dual-Sensor Diagnostic Housing for Rough-Surface AE Detection

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Solution Overview

Problem

Diagnostic sensors using acoustic emission (AE) sensors are affected by surface roughness of mounting members, leading to decreased detection accuracy on the high-frequency side.

Innovation Solution

Incorporating both a vibration sensor and a sound sensor within a housing, with a through hole to guide sound into the housing, allowing detection of high-frequency states through sound propagation, reducing the influence of mounting member surface roughness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If an AE sensor is used to detect high-frequency states, then detection capability on the high-frequency side is improved, but detection accuracy decreases when the mounting member surface is rough

Engineering Contradiction:

Improvedetection accuracy of high-frequency stateVSAvoidinfluence of surface roughness

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a sound sensor as an intermediary device that detects high-frequency states through sound waves in air rather than through direct contact with the mounting member. The sound sensor captures elastic waves that propagate through the air from the detection target, eliminating the need for direct mounting on the rough surface. This intermediary approach allows high-frequency detection without being affected by surface roughness, resolving the contradiction between detection capability and surface condition sensitivity.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Difficulty of detecting and measuring

If an AE sensor is used for high-frequency detection, then detection capability is improved, but placement constraints increase due to surface roughness requirements

Engineering Contradiction:

Improvedetection capability of high-frequency stateVSAvoidplacement constraints

Core Design Contradiction:

Difficulty of detecting and measuringVSEase of operation

Solution Approach 1:

The sound sensor serves as an intermediary that detects high-frequency states through airborne sound waves, allowing the sensor to be positioned away from the mounting member surface. The housing with sound introduction holes enables the sound sensor to capture high-frequency sounds without requiring direct contact with the mounting member, thereby eliminating strict placement constraints while maintaining high-frequency detection capability.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Measurement precision

If a vibration sensor is used alone, then low-frequency detection is achieved, but high-frequency detection capability is insufficient

Engineering Contradiction:

Improvedetection accuracy of low-frequency stateVSAvoiddetection capability of high-frequency state

Core Design Contradiction:

Measurement precisionVSDifficulty of detecting and measuring

Solution Approach 1:

The patent combines a vibration sensor and a sound sensor into a single integrated diagnostic sensor system. The vibration sensor detects low-frequency states through direct mounting on the detection target, while the sound sensor detects high-frequency states through airborne sound waves. By merging these two different detection mechanisms, the system achieves comprehensive frequency range coverage, resolving the contradiction between low-frequency detection accuracy and high-frequency detection capability.

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

Suppresses the decrease in detection accuracy on the high-frequency side while minimizing placement constraints, thereby improving the overall detection accuracy.

Implementation Method 1

a sound sensor configured to output a sound detection signal in response to sound in a space within a second detection frequency range

Methodology Applied

Scientific EffectSound detection: Sound

Implementation Method 2

The facing surface defines a through hole through which the sound is guided into the housing

Methodology Applied

Scientific EffectSound propagation: Sound

Implementation Method 3

a vibration sensor configured to output a vibration detection signal in response to vibration within a first detection frequency range

Methodology Applied

Scientific EffectVibration detection: Vibration

Data Source

PatentEP4722668A1Diagnostic sensor, and state determining system employing same

Publication Date: 2026.04.08 DENSO CORP

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AI summary

A diagnostic sensor includes a vibration sensor (10) configured to output a vibration detection signal in response to vibration within a first detection frequency range, and a sound sensor (20) configured to output a sound detection signal in response to sound in a space within a second detection frequency range, and a housing (50) defining a housing space (50a) in which the vibration sensor and the sound sensor are housed. The second detection frequency range including frequency higher than the first detection frequency range. The housing has a facing surface (51) that faces the mounting member when the diagnostic sensor is mounted on a mounting member, and the facing surface defines a through hole (510) through which the sound is guided into the housing.