Dual-Sensor Diagnostic Housing for Surface-Roughness-Tolerant Detection
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Solution Overview
Problem
Diagnostic sensors using acoustic emission (AE) sensors face reduced detection accuracy due to surface roughness of mounting members, leading to placement constraints.
Innovation Solution
Incorporating a vibration sensor and a sound sensor within a housing with a through hole, where the sound sensor detects sound in a higher frequency range, reducing the influence of mounting member surface roughness and enhancing detection accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If an acoustic emission sensor is used for high-frequency detection, then detection capability in the high-frequency range is achieved, but detection accuracy deteriorates due to surface roughness of the mounting member
Solution Approach 1:
The patent introduces a sound sensor as an intermediary device that detects sound waves in the air rather than directly contacting the mounting member. The sound sensor captures acoustic emissions through the air medium, eliminating the direct contact interface that causes surface roughness interference. This mediator approach allows high-frequency detection while avoiding the harmful effect of surface irregularities on the sensor output
Solution Approach 2:
The patent replaces the mechanical contact-based acoustic emission sensor with a sound sensor that operates on acoustic wave propagation through air. This substitution transitions from a mechanical coupling system (sensor directly mounted on the surface) to an acoustic field-based system, where the sensor detects pressure waves in the air rather than mechanical vibrations through solid contact, thereby eliminating surface roughness effects
2Measurement precision
If a vibration sensor is used for detection, then low-frequency vibration detection is achieved, but high-frequency detection capability is insufficient
Solution Approach 1:
The patent combines a vibration sensor and a sound sensor into a single diagnostic sensor unit. The vibration sensor handles low-frequency detection while the sound sensor handles high-frequency detection. By merging these two different sensing mechanisms with complementary frequency ranges, the system achieves broad-spectrum detection capability covering both low and high frequencies, thereby improving adaptability and versatility
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 diagnostic sensor improves detection accuracy on the high-frequency side by using a sound sensor to detect sound propagating through space, thereby reducing placement constraints and enhancing the overall detection precision.
Implementation Method 1
The sound sensor is configured to output a sound detection signal in response to sound in a space within a second detection frequency range
Implementation Method 2
The vibration sensor is configured to output a vibration detection signal in response to vibration within a first detection frequency range
Data Source
AI summary
A diagnostic sensor includes a vibration sensor configured to output a vibration detection signal in response to vibration within a first detection frequency range, and a sound sensor configured to output a sound detection signal in response to sound in a space within a second detection frequency range, and a housing defining a housing space 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 that faces the mounting member when the diagnostic sensor is mounted on a mounting member, and the facing surface defines a through hole through which the sound is guided into the housing.