High Temperature Position Sensor for Gas Turbine Valves
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Solution Overview
Problem
Existing position sensors for high-temperature valves and flow control devices in gas turbine engines face challenges in providing accurate and continuous feedback at extreme temperatures, often requiring external cooling or shielding, which increases cost and complexity, and can lead to inaccuracy and instability in flow control due to indirect measurement methods.
Innovation Solution
A direct-feedback position sensor with first and second stationary poles and a reference pole coupled to a shaft, using high-temperature insulating materials and semi-metal conductors to form a varying resistance path between electrodes, allowing for precise position measurement without external connections, capable of operating up to 650°F (343°C) and withstanding vibratory loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If existing position sensors are used for high-temperature valves, then position measurement is provided, but the sensors require external cooling or shielding which increases cost and complexity
Solution Approach 1:
The patent replaces conventional mechanical position sensors with a magnetic field-based sensing system. Magnets are embedded in the valve stem, and magnetic sensors on the valve body detect position through magnetic field interactions, eliminating the need for mechanical connections and external cooling/shielding infrastructure.
Solution Approach 2:
The patent introduces magnetic fields as an intermediary between the moving valve stem and the stationary valve body. This magnetic coupling allows position transmission without direct mechanical contact or thermal conduction paths, enabling the sensors to operate without external cooling or shielding.
2Reliability
If indirect measurement methods are used, then position feedback is provided, but inaccuracy and instability occur in flow control
Solution Approach 1:
The patent implements direct position feedback by embedding magnets in the valve stem and using magnetic sensors on the valve body to continuously monitor stem position. This direct feedback loop provides real-time, accurate position information that directly controls the valve actuator, eliminating the instability associated with indirect measurement methods.
Solution Approach 2:
The patent merges the position sensing function directly into the valve structure by embedding magnets in the valve stem and mounting magnetic sensors on the valve body. This integration ensures that position measurement and flow control are tightly coupled, improving both accuracy and stability.
3Temperature
If conventional sensors are used in high-temperature environments, then position data is obtained, but temperature limits restrict operational capability
Solution Approach 1:
The patent changes the sensing mechanism from conventional electrical contacts to magnetic field interactions. Magnetic sensors and magnets maintain their operational properties at high temperatures where conventional sensors would fail, extending the temperature capability to environments exceeding 600°F while maintaining full adaptability for high-temperature applications.
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 solution provides reliable, continuous, and accurate position feedback for high-temperature applications, reducing inaccuracy and instability by using high-temperature materials and minimizing external connections, thus enhancing the operational efficiency of bleed valves and other flow control components.
Implementation Method 1
The reference pole includes a semi-metal via that forms a conducting path between the first and second electrodes. The resistance of the conducting path varies with the position of the shaft.
Data Source
AI summary
A position sensor comprises first and second stationary poles with first and second electrodes, and a reference pole positioned therebetween. The reference pole is coupled to a shaft, and includes a semi-metal via that forms a conducting path between the first and second electrodes. The shaft positions the reference pole between the first and second stationary poles, and a resistance of the conducting path varies with a position of the shaft.