Integrated Sensor Cartridge for Flexible Eddy Current Inspection

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Solution Overview

Problem

The use of flexible eddy current arrays for inspection is limited by durability, performance, and ease-of-use issues, particularly due to the complexity of connectors between the array and instrumentation, which hinders their adoption compared to conventional eddy current testing.

Innovation Solution

An integrated sensor cartridge system with a mechanical support, flexible sensor array, and rigid connector that facilitates simultaneous mechanical and electrical connections, allowing for efficient attachment to an instrument side connector, enabling flexible sensor arrays to conform to various test objects like bolt holes and fillets, and utilizing a robotic arm for precise positioning.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If flexible eddy current arrays are used for inspection, then adaptability to complex surfaces is improved, but connector complexity increases

Engineering Contradiction:

Improveadaptability to complex surfacesVSAvoidconnector complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines the mechanical support structure and electrical connector into a single integrated cartridge assembly. The rigid connector is mechanically coupled to the support structure, eliminating the need for separate connector components and simplifying the overall system while maintaining adaptability to complex surfaces through the flexible sensor array.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated cartridge design serves multiple functions simultaneously: the mechanical support provides structural stability and positioning, the flexible sensor array conforms to complex geometries, and the rigid connector enables electrical connection. This multi-functional integration reduces the number of separate components needed in the inspection system.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If flexible eddy current arrays are used for inspection, then inspection flexibility is improved, but ease of operation deteriorates

Engineering Contradiction:

Improveinspection flexibilityVSAvoidease of operation

Core Design Contradiction:

Adaptability or versatilityVSEase of operation

Solution Approach 1:

By integrating the flexible sensor array with the rigid connector and mechanical support into a single cartridge, the system combines the benefits of flexibility and ease of operation. The pre-assembled nature of the cartridge eliminates complex connection procedures while maintaining the ability to conform to complex inspection surfaces.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If flexible eddy current arrays are used for inspection, then inspection capability on complex surfaces is improved, but durability deteriorates

Engineering Contradiction:

Improveinspection capability on complex surfacesVSAvoiddurability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent employs a flexible sensor array fabricated on a flexible substrate that can conform to complex surfaces while maintaining structural integrity. The flexible nature allows the array to adapt to irregular geometries without compromising durability, as the flexible substrate is designed to withstand repeated bending and conforming motions.

Inventive Principle:

Principle #30Flexible shells and thin films

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

This solution enhances the durability and performance of flexible eddy current arrays by simplifying connections and enabling robust, efficient inspections of complex surfaces, reducing maintenance costs and improving inspection accuracy.

Implementation Method 1

flexible (conformable) eddy current arrays for inspection

Methodology Applied

Scientific EffectEddy currents: Eddy Currents

Data Source

PatentUS10677756B2Integrated sensor cartridge system and method of use

Publication Date: 2020.06.09 JENTEK SENSORS INC

AI summary

A sensor system has an integrated sensor cartridge, and instrument, and an instrument side connector. The integrated sensor cartridge has a mechanical support, a flexible sensor array, and a rigid connector. The mechanical support is shaped to facilitate sensor measurements on a test object. The rigid connector has a mechanical connection and an electrical connection for simultaneous electrical and mechanical mating of the sensor cartridge to the instrument side connector. The flexible array has a connecting portion, a lead portion, and a sensing portion. The sensing portion is attached to the mechanical support, and the connecting portion interfaces with the rigid connector. The connecting portion may form the electrical connection of the rigid connector or may simply mate internally with the electrical connection. The instrument side connector is connected to the instrument which measures the response of the flexible sensor array. Test objects may include bolt holes, fillets, disk slots, and other types of parts or components.