Hyper-redundant Sensor Nodes for Gas Turbine Monitoring
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Solution Overview
Problem
Existing sensor networks in gas turbine engines face high installation costs, reliability issues due to extensive wiring, and inaccuracies in data transmission, with a high probability of wire damage and lack of automatic monitoring for sensor drift and noise.
Innovation Solution
A hyper-redundant monitoring system with multiple sensors measuring the same parameter, connected to a low-cost processor for data analysis and transmission, allowing for wireless communication and reducing the need for extensive wiring, and enabling 'soft' failure modes where individual sensor failures do not disrupt overall functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wired sensors are installed on power and signal lines, then sensor data can be transmitted reliably, but installation costs increase due to extensive wiring
Solution Approach 1:
The patent replaces the mechanical wiring system with wireless communication technology. Sensors transmit data wirelessly to a base station, eliminating the need for extensive power and signal lines while maintaining data transmission capability. This substitution directly reduces installation costs and complexity.
Solution Approach 2:
The patent extracts the communication function from the physical wiring infrastructure by implementing wireless transmission. The sensor nodes independently transmit data without requiring dedicated signal lines, separating the sensing function from the communication infrastructure.
2Measurement precision
If thermocouples are instrumented with wire leads connected to diagnostic units, then temperature monitoring is achieved, but the probability of wire damage increases
Solution Approach 1:
The patent replaces the vulnerable wire lead system with wireless communication. Each thermocouple sensor node transmits temperature data wirelessly to a base station, eliminating physical wire connections that are susceptible to damage in high-temperature turbine environments.
Solution Approach 2:
The patent employs multiple low-cost sensor nodes that can be easily replaced if failed. Rather than protecting expensive wiring infrastructure, the system uses inexpensive wireless sensors that can be quickly swapped out, reducing overall system vulnerability.
3Reliability
If multiple sensors are deployed to monitor the same parameter, then measurement redundancy is achieved, but system complexity increases
Solution Approach 1:
The patent merges multiple sensor nodes into a coordinated network that shares a common communication protocol and data processing architecture. The base station consolidates data from multiple sensors, processing them as a unified system rather than separate independent units.
Solution Approach 2:
The patent creates universal sensor nodes that can monitor multiple parameters (temperature, pressure, vibration) using the same hardware platform and communication interface. This multi-functionality reduces overall system complexity compared to dedicated single-purpose sensors.
Data Source
AI summary
A hyper-redundant monitoring system and a gas turbine including the hyper-redundant monitoring system are provided. The hyper-redundant monitoring system includes a processor, a sensor node operably connected to the processor. The sensor node includes a plurality of sensors disposed in close proximity to one another such that a single parameter is measured by each of the plurality of sensors and each sensor is configured to transmit the parameter. The system also includes a power source and a controller in operable communication with the processor. The single parameter is output by each of the sensors and transmitted to the processor which collects the output parameters, analyzes the output parameters, and transmits analyzed data to the controller.