Vibration Sensor Using Magnetostrictive Drive for High Temperature
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Solution Overview
Problem
Vibration sensors face limitations in high-temperature applications due to mechanical stresses from thermal expansion differences between metal and ceramic materials, leading to failure, and existing electromagnetic drives are less efficient and require more energy, making them unsuitable for explosion-endangered regions.
Innovation Solution
A vibration sensor using a disk-shaped magnetostrictive material connected via a force-transmitting connection to a metal membrane, powered by an electromagnetic drive, which allows efficient operation up to 700-900°C and is suitable for explosion-endangered regions due to reduced energy requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If piezoelectric elements are used to drive the vibration sensor, then high efficiency and low energy consumption are achieved, but the sensor fails at high temperatures due to thermal expansion differences between ceramic and metal materials
Solution Approach 1:
The patent replaces the piezoelectric drive (electromechanical system) with an electromagnetic drive system consisting of a coil and permanent magnet. This substitution eliminates the ceramic material that causes thermal expansion mismatches, allowing the sensor to operate reliably at high temperatures while maintaining efficient energy consumption through electromagnetic actuation.
Solution Approach 2:
The patent changes the material parameters of the drive mechanism from piezoelectric ceramic to electromagnetic components (coil and permanent magnet). This parameter change in the drive system's physical composition enables high-temperature operation by removing the thermal expansion compatibility issue between dissimilar materials while preserving the efficiency benefits of piezoelectric-like performance through electromagnetic actuation.
2Temperature
If electromagnetic drive is used to power the vibration sensor, then high temperature operation is enabled, but energy consumption increases making it unsuitable for explosion-endangered regions
Solution Approach 1:
The patent optimizes the electromagnetic drive parameters by using a permanent magnet to generate a static magnetic field that interacts with the oscillating magnetic field from the coil. This parameter optimization in the electromagnetic system reduces energy consumption to levels suitable for explosion-endangered regions while maintaining the high-temperature operational capability that distinguishes it from piezoelectric drives.
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 a vibration sensor that operates efficiently and reliably at high temperatures with excellent force transfer and reduced energy consumption, suitable for use in high-temperature and potentially explosive environments.
Implementation Method 1
a disc shaped element (9) of a magnetostrictive material is provided, which is connected with the inner surface of the membrane (3) by force transmitting connection (10)
Implementation Method 2
an electromagnetic drive (7), which—as already mentioned above—is suitable without problem for use in the high temperature region
Data Source
AI summary
A vibration sensor comprising an oscillatable unit, which is composed of a membrane with an inner surface and an outer surface and, in given cases, at least one oscillatory element secured on the outer surface of the membrane. A transmitting/receiving unit is provided, which with a predetermined exciter frequency excites the oscillatable unit to execute oscillations and which receives oscillations of the oscillatable unit. A control/evaluation unit is provided, which signals reaching of the predetermined fill level or ascertains the density, respectively the viscosity, of the medium. In order to be able to apply the vibration sensor in high temperature applications, a disc shaped element of a magnetostrictive material is provided, which has a force transmitting connection with the inner surface of the membrane. The transmitting/receiving unit is an electromagnetic drive.