Microwave Sensor Assembly for Proximity Measurement Through Contaminants

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Solution Overview

Problem

Existing sensors, such as eddy current and optical sensors, face limitations in detecting vibrations and position of machine components due to limited detection range, susceptibility to contaminants, and inability to function effectively through liquids or particulates, making them unsuitable for industrial environments.

Innovation Solution

A microwave sensor assembly that uses a signal processing device to generate a pink noise-based microwave signal, which includes a pattern of frequencies, and a probe with an emitter that generates an electromagnetic field. The emitter is detuned when an object is positioned within the field, causing a loading signal that is reflected back, allowing for the calculation of the object's proximity based on the signal processing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If eddy current sensors are used to measure vibrations and position, then measurement capability is provided, but the detection range is limited to only about half of the width of the sensing element

Engineering Contradiction:

Improvedetection rangeVSAvoidsensing element width

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces the mechanical/electromagnetic eddy current sensing system with a microwave electromagnetic sensing system. The microwave sensor uses electromagnetic waves at microwave frequencies to detect object proximity and vibrations, eliminating the need for physical contact or close proximity requirements of eddy current sensors. This substitution enables detection ranges significantly exceeding the sensor dimensions.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If optical sensors are used to measure vibration and position, then measurement capability is provided, but the sensors become fouled by contaminants and provide inaccurate measurements

Engineering Contradiction:

Improvemeasurement accuracyVSAvoidcontaminant fouling

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The patent replaces optical sensing with microwave electromagnetic sensing. Microwave signals can penetrate through many contaminants, liquids, and particulates that would block or scatter optical signals. This substitution eliminates the fouling problem inherent in optical sensors used in industrial environments.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Measurement precision

If optical sensors are used to detect vibration and position, then measurement capability is provided, but the sensors cannot detect through liquid medium or particulates

Engineering Contradiction:

Improvedetection capabilityVSAvoidenvironmental compatibility

Core Design Contradiction:

Measurement precisionVSAdaptability or versatility

Solution Approach 1:

The patent replaces optical detection with microwave electromagnetic detection. Microwave signals have the ability to penetrate through liquids, gases, and particulate matter, enabling the sensor to detect object proximity and vibrations through media that completely block optical signals. This provides versatility for use in diverse industrial environments including those with liquids and particulates.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 microwave sensor assembly provides a stable and robust proximity measurement with a substantially linear response over a range of distances, overcoming the limitations of traditional sensors by increasing detection range and maintaining accuracy in industrial environments, including through liquids and particulates.

Implementation Method 1

The probe includes an emitter configured to generate an electromagnetic field from the at least one microwave signal

Methodology Applied

Scientific EffectElectromagnetic field generation: Electromagnetic Induction

Implementation Method 2

a loading signal is reflected from the emitter to the signal processing device

Methodology Applied

Scientific EffectElectromagnetic reflection: Reflection

Implementation Method 3

the emitter is detuned when an object is positioned within the electromagnetic field

Methodology Applied

Scientific EffectElectromagnetic detuning: Resonance

Data Source

PatentUS8854052B2Sensor assembly and method of measuring the proximity of a machine component to a sensor

Publication Date: 2014.10.07 BAKER HUGHES CO

AI summary

A microwave sensor assembly includes a signal processing device for generating at least one microwave signal that includes a pattern of frequencies and at least one probe coupled to the signal processing device. The probe includes an emitter configured to generate an electromagnetic field from the at least one microwave signal, wherein the emitter is detuned when an object is positioned within the electromagnetic field such that a loading signal is reflected from the emitter to the signal processing device.