Handheld Impedance Measurement Assembly With Integrated Sensor Coupling
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Solution Overview
Problem
There is a need for high-performance, non-destructive testing (NDT) equipment that is portable, lightweight, and easily interchangeable, with compatibility for robotic manipulators, and capable of measuring impedance in a handheld format.
Innovation Solution
A portable impedance measurement system with a cylindrical housing, featuring an eddy-current sensor or capacitive sensor array, a board stack for driving electrical signals and measuring responses, and a communication module connected to a processor, which includes a mechanical and electrical connector system for attaching sensors and providing power management and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the measurement system is made portable and handheld, then the housing size is reduced, but the device complexity increases due to integrating multiple functions in a compact space
Solution Approach 1:
The measurement system is divided into separate functional modules: a handheld impedance instrument with housing, and interchangeable sensor cartridges. This segmentation allows the main instrument to remain compact while sensor functionality is distributed to separate cartridges that can be attached as needed, reducing the volume of the moving handheld device while maintaining full measurement capabilities.
Solution Approach 2:
The impedance instrument is designed with universal interfaces and a standardized connector system that can work with multiple types of sensor cartridges. The single housing contains power management, signal processing, and communication modules that can support various sensing modalities (eddy-current, capacitive, other impedance-based sensors), allowing one device to perform multiple measurement functions without increasing its base volume.
2Ease of operation
If interchangeable sensor cartridges are implemented, then the ease of operation improves, but the device complexity increases due to the connector system
Solution Approach 1:
The mechanical attachment and electrical connection functions are merged into a single integrated connector interface. When the sensor cartridge is mechanically attached to the handheld instrument, electrical contacts are simultaneously engaged through the same interface structure. This merging eliminates the need for separate mechanical fastening and electrical plugging steps, making the interchange operation simple while the integrated design manages the complexity internally.
Solution Approach 2:
The connector system is designed to automatically align and engage electrical contacts when the sensor cartridge is mechanically attached. The interface includes self-aligning features and spring-loaded contacts that make electrical connection as the cartridge is inserted, without requiring manual wiring or complex alignment procedures. This self-service mechanism simplifies the user operation while the automatic alignment and contact engagement mechanisms manage the internal complexity.
3Reliability
If power management and heat dissipation are integrated into the handheld device, then the reliability improves, but the device complexity increases
Solution Approach 1:
Power management and heat dissipation components are nested within the housing structure. The housing contains integrated power regulation circuits, battery management systems, and thermally conductive pathways that are built into the device architecture. These nested components manage power distribution and heat removal without adding external attachments or separate systems, improving reliability through integrated control while containing complexity within the housing boundaries.
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 enables high-performance, non-destructive testing in a compact, handheld format with interchangeable sensor cartridges, compatible with robotic tools, and efficient power management, facilitating real-time impedance measurement and analysis.
Implementation Method 1
the end-effector comprises an eddy-current sensor
Implementation Method 2
the end-effector comprises a capacitive sensor
Data Source
AI summary
A measurement system, its assembly and use are disclose. The system may include an instrument for making sensor measurements. The instrument has a substantially cylindrical housing. The shape and size allow the instrument to easily fit in an average hand enabling handheld operation. The housing houses a board stack of electronic boards. These electronics drive an electrical signal in at least one drive channel and measure responses from at least two sensing channels. These responses are provided to a processor for analysis. The instrument has a sensor connector that enables simultaneous electrical and mechanical attachment of an end effector.