Ultrasonic Patch Transducer With Magnetic Self-Alignment for Asset Monitoring

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Solution Overview

Problem

Existing ultrasonic transducers for monitoring structural assets face challenges such as large size, high cost, inability to deploy in groups, limited heat resistance, lack of integrated sensors for temperature measurement, and difficulty in proper alignment, which restrict their effectiveness and applicability.

Innovation Solution

The development of an ultrasonic patch transducer with a housing, piezoelectric element, magnets, and sensors, designed for securement to structural assets, allowing self-alignment and temperature compensation, and capable of withstanding high temperatures, enabling distributed sensing and accurate measurements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional ultrasonic transducers are used, then monitoring function is provided, but size is large and cost is high

Engineering Contradiction:

Improvemonitoring functionVSAvoidtransducer size

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The patent divides the ultrasonic monitoring system into separate functional components: a compact ultrasonic transducer module for emitting/receiving waves and a separate processing unit for analyzing signals. This segmentation allows the transducer itself to be miniaturized while maintaining full monitoring capability through the distributed network of multiple small transducers.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent uses multiple copies of simplified, smaller transducer units deployed in arrays along the structural asset. Instead of relying on a single large transducer, multiple compact transducers work together to provide comprehensive monitoring coverage, effectively replacing one large unit with many smaller ones.

Inventive Principle:

Principle #26Copying

2Reliability

If traditional ultrasonic transducers are used, then monitoring is possible, but they cannot be deployed as a group for distributed sensing

Engineering Contradiction:

Improvemonitoring capabilityVSAvoiddistributed sensing capability

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The system segments the monitoring function across multiple independent transducer units that can be individually deployed along the structural asset. Each unit operates autonomously but contributes to the overall distributed sensing network, enabling flexible placement at various locations including elbows and circumferential positions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The transducer design incorporates universal mounting features and standardized interfaces that allow the same unit to be deployed in various configurations and locations. The transducers can function independently or as part of an array, providing multi-functional adaptability for different monitoring scenarios.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If traditional ultrasonic transducers are used, then monitoring function is provided, but alignment positioning is difficult

Engineering Contradiction:

Improvemonitoring functionVSAvoidalignment ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent replaces complex mechanical alignment systems with magnetic coupling mechanisms. Magnets embedded in the transducer housing automatically align the device with the structural asset surface through magnetic attraction, eliminating the need for manual mechanical positioning and ensuring consistent orientation without complex adjustment mechanisms.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The transducer incorporates self-aligning features where the magnetic coupling and housing geometry automatically position the device correctly upon attachment. The design includes self-centering mechanisms that guide the transducer into proper alignment during installation, reducing the skill level required for installation and ensuring repeatable positioning.

Inventive Principle:

Principle #25Self-service

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 cost-effective, compact, and accurately aligned transducers that can withstand high temperatures, facilitating true distributed sensing and improved condition monitoring of structural assets with enhanced temperature measurement capabilities.

Implementation Method 1

a piezoelectric element within the housing and positioned along the centerline

Methodology Applied

Scientific EffectPiezoelectric effect: Piezoelectric Effect

Implementation Method 2

at least two magnets within the housing and positioned along the centerline

Methodology Applied

Scientific EffectMagnetic force: Magnetism

Data Source

PatentUS12449404B2Ultrasonic patch transducer for monitoring the condition of a structural asset

Publication Date: 2025.10.21 MOLEX INC

AI summary

An ultrasonic patch transducer is configured to be secured to an outer surface of a structural asset, such as a pipe or pressure vessel, for condition monitoring. The ultrasonic patch transducer includes a housing defining a centerline between a first end of the housing and a second end of the housing, a piezoelectric element within the housing and positioned along the centerline, and at least two magnets within the housing and positioned along the centerline. The at least two magnets and the piezoelectric element are configured to be positioned along a tangent plane of the structural asset.