Fiber Optic Sensor Carrier with Breakaway Tabs
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Solution Overview
Problem
Conventional electrical resistance strain gages used for bearing thrust loading measurements are prone to errors due to temperature dependence, mechanical fatigue, electromagnetic interference, and require absolute calibration, failing to effectively manage thrust loads and extend bearing life.
Innovation Solution
A fiber optic sensing system with a carrier and breakaway tabs that securely attaches a fiber optic cable to a bearing housing, maintaining tension and using a compensation fiber to correct for temperature-induced shifts, providing robust and repeatable thrust and temperature measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If electrical resistance strain gages are used for bearing thrust loading measurement, then the measurement can be obtained, but the measurement is prone to errors due to temperature dependence, mechanical fatigue, electromagnetic interference, and requires absolute calibration
Solution Approach 1:
The patent replaces electrical resistance strain gages with fiber optic sensors that use optical principles (interferometry) to measure thrust loading. The fiber optic sensor detects changes in light phase, frequency, or intensity caused by mechanical deformation, eliminating susceptibility to electromagnetic interference and temperature drift that plagues electrical gages. This substitution of measurement physics fundamentally resolves the reliability issue while maintaining measurement precision.
Solution Approach 2:
The invention uses a compensation fiber optic sensor that experiences the same temperature environment as the measurement sensor but is isolated from mechanical loading. By measuring temperature-induced optical parameter changes in the compensation sensor and subtracting these from the measurement sensor readings, the system eliminates temperature dependence errors and achieves stable, drift-free measurements.
2Measurement precision
If strain gages are used to measure bearing thrust, then thrust load measurement is achieved, but the strain gages are subject to mechanical fatigue failure and loss of signal
Solution Approach 1:
The patent replaces mechanical strain gages that are susceptible to fatigue failure with fiber optic sensors that have no moving parts and are inherently resistant to mechanical fatigue. The optical fiber measures strain through changes in light propagation properties caused by mechanical deformation of the fiber itself, eliminating the adhesive bonding and electrical connections that fail under cyclic loading, thereby dramatically extending sensor service life.
3Measurement precision
If strain gages are used for thrust measurement, then measurement is obtained, but the strain gages are subject to electrical magnetic interference or other induced electrical noise
Solution Approach 1:
The patent replaces electrical resistance strain gages that convert mechanical strain into electrical signals with fiber optic sensors that convert mechanical strain into optical signal changes. Since optical fibers are dielectric materials that do not conduct electricity, they are completely immune to electromagnetic interference and induced electrical noise, resolving the susceptibility problem while maintaining measurement accuracy.
4Measurement precision
If electrical resistance strain gage is used, then thrust measurement is achieved, but the gage factor varies as a function of temperature and produces error
Solution Approach 1:
The invention employs a compensation fiber optic sensor that is exposed to the same temperature conditions as the measurement sensor but is mechanically isolated from the thrust loading. The compensation sensor measures only temperature-induced optical parameter changes, which are then subtracted from the measurement sensor readings to eliminate temperature dependence and produce accurate thrust measurements across varying temperature conditions.
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 offers accurate, reliable, and immune-to-EMI measurements, enabling real-time monitoring and extended bearing life by minimizing thrust-related downtime and errors, while maintaining sensor integrity under varying loads.
Implementation Method 1
a fiber optic sensor includes a fiber optic cable and a carrier
Data Source
AI summary
A system and method for assembling a fiber optic sensor assembly are provided. The fiber optic sensor system includes a fiber optic cable and a carrier including a first connection end and a second connection end joined together by one or more breakaway tabs, the first connection end including a first fiber attach point configured to secure a distal end of the fiber optic cable to the first connection end, the second connection end including a second fiber attach point configured to secure the fiber optic cable to the second connection end, the one or more breakaway tabs joined to the first connection end and the second connection end using a break area that is structurally weaker than the carrier and the breakaway tabs.