Optic Fiber Sensor Routing in Harsh Environments
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Solution Overview
Problem
Existing sensing systems for gas turbine engines face challenges in accessing difficult locations due to moving parts and harsh environments, leading to bulky, expensive, and vulnerable wire routing, and optic fiber communication systems are limited in extreme conditions.
Innovation Solution
A multiplexed sensor system using optic fibers routed through a protected channel that shields and cools the fibers, allowing communication with multiple sensors over a common fiber, and includes a power and data bus for actuators, with features like fault detection and redundancy to enhance reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wire routing is used for sensor communication in difficult locations, then communication with sensors is achieved, but the system becomes bulky, expensive and vulnerable to interconnect failures
Solution Approach 1:
The patent replaces traditional electrical wire routing with optical fiber communication. The optical fibers transmit sensor signals from difficult-to-access locations (such as inside gas turbine engines) to external monitoring systems, eliminating the need for bulky electrical connectors and reducing vulnerability to electromagnetic interference and connection failures.
Solution Approach 2:
The patent introduces optical fibers as an intermediary medium between sensors in harsh environments and the external control system. The fibers act as a protected communication channel that can withstand extreme temperatures, pressures, and mechanical stresses that would damage traditional electrical wiring.
2Adaptability or versatility
If optic fibers are routed through harsh environments, then sensor communication is enabled, but the optic fibers are exposed to extreme temperature and pressure conditions
Solution Approach 1:
The patent nests the optical fibers within a protective conduit or channel that is itself installed within the harsh environment. This nested structure provides multiple layers of protection - the conduit shields the fibers from extreme temperatures, pressures, and mechanical damage while still allowing the fibers to reach sensors in difficult locations.
Solution Approach 2:
The protective conduit acts as an intermediary between the harsh environment and the optic fibers. It absorbs and mitigates the harmful environmental factors (extreme heat, pressure, vibration) before they can affect the delicate optical fibers, enabling reliable communication in previously inaccessible locations.
3Quantity of substance
If traditional wire routing is used, then sensor data can be transmitted, but cable cost, volume and weight exceed allowable limits
Solution Approach 1:
The patent substitutes optical fibers for traditional heavy electrical cables. Optical fibers have significantly lower density and smaller diameter, reducing both weight and volume by factors of 10 or more while maintaining signal transmission capability. This enables sensor networks in weight-critical applications such as aerospace and automotive engines.
Solution Approach 2:
The patent employs a multi-functional optical fiber bundle that can simultaneously transmit multiple sensor signals, power, and control commands through a single integrated conduit system. This consolidates what would otherwise require multiple separate cable runs, reducing overall installation complexity and space requirements.
4Reliability
If optic fiber communication devices are used in controlled environments, then sensor communication works reliably, but they cannot be utilized in harsh environments with extreme pressure and temperature
Solution Approach 1:
The patent modifies the operational parameters of the optical fiber system to withstand harsh environments. This includes selecting specialized fiber types with appropriate thermal expansion coefficients, using protective coatings and conduits rated for extreme temperatures and pressures, and designing expansion compensation mechanisms that maintain optical alignment despite thermal cycling and mechanical stress.
Solution Approach 2:
The patent employs composite protective structures combining multiple materials with complementary properties - such as ceramic coatings for thermal protection, metallic alloys for mechanical strength, and polymer layers for environmental sealing. These composite constructions enable the optical fiber system to survive and operate reliably in previously prohibitive environments.
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 system effectively communicates sensor data in harsh environments, reduces weight and cost, and enhances reliability by minimizing electromagnetic interference and allowing for easy maintenance and sensor additions without hardware changes.
Implementation Method 1
A cooling flow is provided through the protective channel for minimizing temperature fluctuations within the protective channel
Data Source
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AI summary
A multiplexed sensor system (78) includes a control unit (62) in communication with a plurality of sensors (64, 66, 68, 82). A plurality of optic fibers (74A, 74B) that defines a communication path between the sensors and the control unit. A multiplexing portion (67) communicates with the sensors along a common one of the optic fibers and a protected channel (72) through which at least a portion of the optic fibers are routed. The protected channel at least partially surrounds and shields the optic fibers from an environment outside the protected channel. A cooling flow is provided through the protective channel for minimizing temperature fluctuations within the protective channel.