Embedded Sensor Array for Power Cable Condition Monitoring
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Solution Overview
Problem
Current electrical power cables face challenges in optimizing current-carrying capacity and managing risk of failure, particularly in variable environments, due to limitations in predicting temperature rise and mechanical stresses, leading to conservative designs and inefficiencies, as well as increased size and weight from built-in design margins.
Innovation Solution
The integration of a sensor array within the cable, comprising semiconductor sensor chips and communication chips, to monitor temperature, acceleration, strain, material incursion, and magnetic fields at multiple locations, allowing for real-time data communication and reduction of electrical current to prevent failure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If built-in design margins are incorporated into cable specifications, then reliability is improved, but cable size and weight increase
Solution Approach 1:
The patent applies dynamics by transitioning from static design margins to dynamic real-time monitoring and adjustment. Sensor arrays continuously measure temperature, strain, and other parameters, allowing the cable system to adapt its operational capacity based on actual conditions rather than relying on fixed conservative design margins, thereby reducing unnecessary weight while maintaining reliability
Solution Approach 2:
The patent implements feedback through embedded sensor arrays that continuously monitor cable conditions (temperature, strain, material incursion) and provide real-time data. This feedback loop enables dynamic adjustment of current-carrying capacity based on actual cable state, eliminating the need for excessive design margins and reducing cable weight while maintaining reliability
2Reliability
If built-in design margins are incorporated into cable specifications, then reliability is improved, but cable cost increases
Solution Approach 1:
The patent applies dynamics by transitioning from static design margins to dynamic real-time monitoring and adjustment. Sensor arrays continuously measure temperature, strain, and other parameters, allowing the cable system to adapt its operational capacity based on actual conditions rather than relying on fixed conservative design margins, thereby reducing unnecessary weight while maintaining reliability
Solution Approach 2:
The patent implements feedback through embedded sensor arrays that continuously monitor cable conditions (temperature, strain, material incursion) and provide real-time data. This feedback loop enables dynamic adjustment of current-carrying capacity based on actual cable state, eliminating the need for excessive design margins and reducing cable weight while maintaining reliability
3Reliability
If conservative design is used to predict temperature rise, then reliability is improved, but current-carrying capacity is reduced
Solution Approach 1:
The patent applies dynamics by transitioning from static design margins to dynamic real-time monitoring and adjustment. Sensor arrays continuously measure temperature, strain, and other parameters, allowing the cable system to adapt its operational capacity based on actual conditions rather than relying on fixed conservative design margins, thereby reducing unnecessary weight while maintaining reliability
Solution Approach 2:
The patent implements feedback through embedded sensor arrays that continuously monitor cable conditions (temperature, strain, material incursion) and provide real-time data. This feedback loop enables dynamic adjustment of current-carrying capacity based on actual cable state, eliminating the need for excessive design margins and reducing cable weight while maintaining reliability
4Weight of moving object
If optimization of cable size is performed, then weight is reduced, but risk of failure increases
Solution Approach 1:
The patent implements feedback through embedded sensor arrays that continuously monitor cable conditions (temperature, strain, material incursion) and provide real-time data. This feedback loop enables dynamic adjustment of current-carrying capacity based on actual cable state, eliminating the need for excessive design margins and reducing cable weight while maintaining reliability
Solution Approach 2:
The patent replaces mechanical/physical design margins with an electronic monitoring and control system. Instead of relying on oversized cable construction to prevent failure, the system uses sensor arrays and real-time data processing to detect and respond to potential failure conditions, enabling optimized cable design with reduced weight while maintaining or improving reliability
Data Source
AI summary
Semiconductor sensor chips are assembled with semiconductor communication chips to form sensor nodes which are wired together and placed in a tube preform which is sealed to form a tube containing an array of sensor nodes. The tube, resembling a wire in appearance, can then be assembled with power conductors to form a power delivery cable to allow monitoring of conditions within the cable at a plurality of spaced locations along the length of the cable so that the cable can be operated near or at its actual current carrying capacity which may be altered by ambient conditions and allowing management of risk of failure of the cable.