Handheld Impedance Instrument With Interchangeable Sensor Cartridges
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Solution Overview
Problem
The need for high-performance, non-destructive testing (NDT) equipment in a portable format that allows for easily interchangeable sensor cartridges and compatibility with robotic manipulators.
Innovation Solution
A measurement system comprising a substantially cylindrical impedance instrument with an end-effector, a sensor mechanism, and a board stack that includes a processor, communication module, and energy storage device, designed for handheld operation and robotic integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the impedance instrument is designed in a handheld format with a substantially cylindrical housing, then portability and ease of operation are improved, but the internal space for accommodating board stack and components is reduced
Solution Approach 1:
The patent implements a nested board stack configuration where multiple electronic boards (driver board, channel board, power board) are stacked vertically within the cylindrical housing. Each board contains specific functional components, and the stacking arrangement maximizes the use of vertical space within the constrained cylindrical volume, allowing all necessary components to fit within the handheld form factor.
2Adaptability or versatility
If sensor cartridges are made interchangeable and easily attachable, then adaptability and ease of operation are improved, but the connector design and alignment precision become more complex
Solution Approach 1:
The patent employs asymmetric alignment features including a keyway in the sensor cartridge that matches a corresponding protrusion in the end effector, along with asymmetric positioning pins and slots. This asymmetric design ensures only correct orientation is possible, simplifying the attachment process while maintaining precise alignment. The mechanical connector includes asymmetric features that guide the electrical connector pins into proper alignment during the attachment motion.
Solution Approach 2:
The patent integrates electrical and mechanical connections so that a single mechanical attachment motion simultaneously establishes both mechanical structural connection and electrical contact. The mechanical connector and electrical connector are coupled such that the attachment of the sensor cartridge to the end effector automatically engages both connection types, eliminating the need for separate alignment and connection steps.
3Ease of operation
If the housing diameter is reduced to less than 2.5 inches for portability, then ease of operation is improved, but the space for heat dissipation and component mounting is reduced
Solution Approach 1:
The patent implements localized thermal management by placing heat-generating components (such as the power board with voltage regulators and the driver board with signal generators) in specific regions of the housing where heat can be efficiently dissipated. The board stack configuration positions these components near the housing walls or near each other to facilitate heat transfer to the housing structure, which acts as a heat sink. This localized approach allows effective thermal management within the constrained volume.
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 with a lightweight, handheld format and compatibility with robotic manipulators, facilitating efficient and versatile impedance measurements.
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.