Flexible PCB Magnetostrictive Sensor for Structural Monitoring
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Solution Overview
Problem
Traditional magnetostrictive sensors are rigid and limited in deployment applications, requiring custom manufacture and manual, labor-intensive construction, making them inflexible for use on various structure geometries and prone to variability.
Innovation Solution
A flexible magnetostrictive sensor implemented on a printed circuit board (PCB) with alternating current (AC) coils, a direct current (DC) bias coil, and a magnetostrictive material strip, allowing for easy manufacturing and deployment on diverse structures, with the ability to concatenate sensors for larger applications and adjust length as needed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional rigid MS sensor construction is used, then manufacturing precision can be maintained, but adaptability to different structure geometries deteriorates
Solution Approach 1:
The patent applies this principle by constructing the sensor on a flexible PCB substrate that can conform to various geometries. The flexible PCB allows the sensor to adapt to different structure shapes while maintaining electrical connections and sensor functionality, directly resolving the contradiction between adaptability and construction complexity.
Solution Approach 2:
The patent divides the sensor into modular segments that can be concatenated to form larger sensors. This segmentation allows the sensor to be adapted to different sizes and geometries by combining multiple standardized modules, improving adaptability without proportionally increasing construction complexity.
2Productivity
If manual hand wrapping of wire windings is used, then manufacturing precision can be achieved, but productivity deteriorates
Solution Approach 1:
The patent replaces the manual mechanical process of hand wrapping wire windings with an automated PCB manufacturing process. The coil windings are created through printed circuit board fabrication techniques, eliminating manual labor while maintaining manufacturing precision and significantly improving productivity.
Solution Approach 2:
The patent uses PCB printing techniques to create precise coil patterns that replicate the function of hand-wrapped windings. This copying approach allows for consistent, repeatable manufacturing without requiring skilled technicians, thereby improving productivity while maintaining ease of manufacture.
3Adaptability or versatility
If fixed size sensors are manufactured, then manufacturing precision can be maintained, but adaptability to different applications deteriorates
Solution Approach 1:
The patent creates sensors in standardized modular segments that can be concatenated to form custom-length sensors. This allows a single manufacturing process to produce versatile sensors that can be adapted to different application sizes without requiring custom manufacture for each application, improving both adaptability and ease of manufacture.
Solution Approach 2:
The patent designs a universal sensor platform using standardized PCB segments that can be applied to multiple different structures and applications. The same basic sensor unit can be deployed on pipes, plates, or other geometries by adjusting the number and arrangement of segments, eliminating the need for custom manufacture while maintaining manufacturing precision.
4Use of energy by moving object
If DC bias voltage is applied continuously, then magnetic field strength is maintained, but energy consumption increases
Solution Approach 1:
The patent applies DC bias voltage in periodic pulses rather than continuously. This pulsed approach maintains the necessary magnetic field strength for reliable sensor operation during active periods while allowing energy consumption to be reduced during idle periods, resolving the contradiction between energy usage and field strength maintenance.
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 flexible PCB design simplifies manufacturing, increases reliability, and enables the sensor to conform to various geometries, enhancing deployment possibilities and sensor performance by allowing higher magnetic field strengths and wave amplitudes.
Implementation Method 1
the approach relies on the MS (or Joule) effect which is the manifestation of small changes in the physical dimensions of ferromagnetic materials caused by an externally applied magnetic field
Implementation Method 2
For receiving elastic waves, it relies on the inverse MS (or Villari) effect which is a change in the magnetic induction of a ferromagnetic material caused by a mechanical stress or strain
Implementation Method 3
The upper and lower AC coils may be energized with an AC tone burst which generates an alternating magnetic field in the MS strip
Implementation Method 4
The DC bias coil may be energized with a voltage pulse. The voltage pulse may be of sufficient duration to provide the magnetic bias when the sensor is in operation, allowing for higher magnetic field strengths, and thus increased wave amplitude and sensor performance
Data Source
AI summary
A flexible printed circuit board (PCB) magnetostrictive (MS) sensor comprising a first direct current (DC) bias PCB layer comprising a first plurality of conductive traces, a first alternating current (AC) PCB layer disposed on the first DC bias PCB layer, the first AC PCB layer comprising a first AC coil, a pocket PCB layer disposed on the first AC PCB layer, the pocket PCB layer to receive a strip of MS material, a second AC PCB layer disposed on the pocket PCB layer, the second AC PCB layer comprising a second AC coil, and a second DC bias PCB layer disposed on the second AC PCB layer, the second DC bias PCB layer comprising a second plurality of conductive traces. The traces from the first plurality of conductive traces are electrically coupled to traces from the second plurality of conductive traces.