Combustible Gas Sensor Power Reduction via Electronic Compensation
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Solution Overview
Problem
Conventional combustible gas sensors face challenges with high power consumption and cost due to the need for a compensating element that matches the sensing element in size and environmental responses, and mechanical supports for smaller sensing elements increase power requirements by conducting heat away from the elements.
Innovation Solution
A combustible gas sensor design featuring a first and second sensing element with support elements having a high tensile strength-to-thermal conductivity quotient, allowing for smaller diameters and reduced power consumption, along with electronic circuitry that cycles between higher and lower power modes to compensate for ambient temperature changes, eliminating the need for a separate compensating element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a compensating element is used to minimize the impact of secondary effects on sensor output, then measurement precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent removes the separate compensating element from the sensor structure and extracts its function to be performed electronically through a microprocessor that calculates compensation based on signals from a temperature sensor and stored compensation data, thereby simplifying the physical device while maintaining measurement precision
Solution Approach 2:
The patent replaces the mechanical/physical compensating element with an electronic compensation system using a microprocessor and temperature sensor, substituting physical structure with computational processing to achieve the same measurement accuracy
2Use of energy by moving object
If the sensing element size is reduced to lower power consumption, then energy efficiency is improved, but mechanical strength decreases requiring additional support structures
Solution Approach 1:
The patent changes the physical parameters of the sensing element by reducing its diameter to 3 micrometers or less, which significantly lowers power consumption while the element is supported by a structure that minimizes thermal interference
Solution Approach 2:
The patent introduces a support structure as an intermediary element that holds the fragile small-diameter sensing element in position while being designed to minimize thermal conduction away from the sensing element, thus providing mechanical support without compromising thermal efficiency
3Stability of the object's composition
If mechanical support structures are added to hold smaller sensing elements, then structural stability is improved, but power consumption increases due to heat conduction
Solution Approach 1:
The patent applies local quality by designing the support structure with specific thermal properties - using materials and geometries that provide adequate mechanical support at the location of the sensing element while minimizing thermal conduction, thus creating a localized solution that addresses both support and thermal efficiency
4Measurement precision
If a separate compensating element is used to track environmental changes, then measurement precision is improved, but manufacturing cost increases
Solution Approach 1:
The patent extracts the compensation function from a separate physical element and implements it through electronic processing using a microprocessor and temperature sensor, eliminating the need to manufacture and match separate compensating elements and thereby reducing production costs
Solution Approach 2:
The patent uses a temperature sensor to detect environmental temperature changes and copies this information into the microprocessor, which then applies compensation algorithms to correct the sensing element readings, creating a virtual copy of the environmental effects for computational compensation
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 design reduces power requirements, decreases the impact of humidity and pressure changes, and extends sensor life while lowering production costs, as the sensing elements can operate efficiently at lower power levels and maintain accuracy without a separate compensating element.
Implementation Method 1
combustible gas sensors operate by catalytic oxidation of combustible gases
Implementation Method 2
a conventional combustible gas sensor 10 typically includes an element such as a platinum element wire or coil 20 encased in a refractory (for example, alumina) bead 30, which is impregnated with a catalyst (for example, palladium or platinum) to form an active or sensing element
Implementation Method 3
the rate of oxidation of the combustible gas may be measured in terms of the variation in resistance of sensing element or pelement 40 relative to a reference resistance
Implementation Method 4
mechanical supports for smaller sensing elements increase power requirements by conducting heat away from the elements
Implementation Method 5
Bead 30 will react to phenomena other than catalytic oxidation that can change its output (i.e., anything that changes the energy balance on the bead) and thereby create errors in the measurement of combustible gas concentration. Among these phenomena are changes in ambient temperature, humidity and pressure.
Data Source
Figure 1A~1C
Figure 2A~2D
Figure 3A
AI summary
A combustible gas sensor includes at least a first sensing element comprising a first conductive element having, for example, an average diameter less than 20µm in electrical connection with electronic circuitry. The combustible gas sensor further includes a first support element having a first anchored end, a second anchored end and an extending intermediate section between the first anchored end and the second anchored end, the extending intermediate section providing support for the first conductive element. Another combustible gas sensor includes a first sensing element and a second sensing element. The first sensing element includes a first catalyst support member having a volume less than a sphere having a diameter of 500µm. The second sensing element includes a second catalyst support member having a volume less than a sphere having a diameter of 500µm. The combustible gas sensor further includes electronic circuitry that is adapted to cycle between a first mode in which the first sensing element is operated in a higher power mode and the second sensing element is operated in a lower power mode and a second mode in which the second sensing element is operated in a higher power mode and the first sensing element is operated in a lower power mode.