Handheld Impedance Instrument With Interchangeable Sensor Cartridge
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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 a sensor cartridge with a flexible sensor and mechanical support, and a processor for data processing, which includes an eddy-current sensor or capacitive sensor, and a power board for power management, allowing for simultaneous measurement of impedance components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If high-performance NDT equipment is designed with traditional structures, then measurement precision is improved, but portability and device size deteriorate
Solution Approach 1:
The measurement system is divided into separate functional modules: a handheld instrument containing control electronics and a separate sensor cartridge containing the eddy-current or capacitive sensors. This segmentation allows the sensing function to be lightweight and portable while maintaining measurement precision through dedicated sensor design.
Solution Approach 2:
Traditional mechanical NDT equipment is replaced with electronic impedance measurement systems using eddy-current sensors or capacitive sensors that measure material properties through electromagnetic fields rather than mechanical contact, significantly reducing device weight while maintaining or improving measurement precision.
2Adaptability or versatility
If sensor cartridges are made interchangeable for robotic manipulators, then adaptability is improved, but device complexity increases
Solution Approach 1:
The sensor cartridge is designed as a universal interchangeable module that can be attached to different robotic manipulators and handheld instruments through standardized connectors. The cartridge contains both mechanical mounting features and electrical connectors that work across multiple platforms, providing adaptability without requiring custom designs for each application.
Solution Approach 2:
The sensor cartridge采用嵌套设计，将传感器元件、机械支撑结构、电气连接器和定位特征嵌套在一个紧凑的 cartridge 外壳中。这种嵌套结构使得复杂的传感器系统可以作为一个整体模块进行 interchange，简化了与机器人操纵器的接口。
3Ease of operation
If sensor and connector alignment is achieved in single motion, then ease of operation is improved, but manufacturing precision requirements increase
Solution Approach 1:
The sensor cartridge is pre-assembled with the sensor element, mechanical support, and electrical connector in a fixed relative position before attachment to the instrument. Alignment features such as positioning pins or keyed connectors are pre-configured to ensure correct orientation, so that the final attachment motion automatically achieves proper alignment without requiring manual adjustment during operation.
Solution Approach 2:
Mechanical alignment features such as positioning pins, keyed connectors, or guide surfaces act as intermediaries between the sensor cartridge and instrument connector. These intermediary elements physically guide the cartridge into correct alignment during the attachment motion, ensuring precise electrical and mechanical connection without requiring high precision from the operator.
4Weight of moving object
If housing diameter is reduced for handheld format, then portability is improved, but internal space for electronics deteriorates
Solution Approach 1:
The electronics are arranged in a compact board stack configuration where multiple functional boards are stacked vertically within the cylindrical housing. This three-dimensional stacking approach maximizes the use of internal volume in the radial direction while keeping the housing diameter small for handheld portability. The board stack extends along the axial dimension rather than requiring large radial space.
Solution Approach 2:
Multiple electronic functional modules are nested within the cylindrical housing in a compact arrangement. The sensor cartridge itself acts as a nested module, containing the sensor element, mechanical support, and electrical connector within a compact structure that fits into the handheld instrument. This nested arrangement allows sufficient electronics to be accommodated in a small diameter housing.
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
Enables high-performance, non-destructive testing in a compact, handheld format with interchangeable sensor cartridges, compatible with robotic tools, and efficient impedance measurement, addressing the need for portability and ease of use.
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.