Passive Resonant Sensor Array for Power-Free Conveyor Monitoring
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Solution Overview
Problem
Conveyor systems with embedded sensors face challenges in continuously monitoring conditions without requiring on-belt power sources, as existing solutions either need recharging, add weight, or compromise the belt's integrity.
Innovation Solution
Integration of resonant circuits with inductors and capacitors in the conveyor belt, coupled with external stationary measurement circuits, allows for continuous monitoring of conditions such as weight, temperature, and humidity without the need for on-belt power, using changes in resonant frequency to detect variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If on-belt batteries, storage capacitors, or energy-harvesting devices are used to power sensors, then sensor measurements can be made and transmitted, but the devices require recharging or replacement, take up space, add weight, or weaken the belt
Solution Approach 1:
The patent extracts the power source from the moving conveyor belt system and places it in a stationary external system. Sensors embedded in the belt remain passive and unpowered, while all power supply, signal processing, and transmission functions are relocated to stationary units outside the belt, eliminating the need for on-belt batteries or energy-harvesting devices
Solution Approach 2:
The patent introduces magnetic coupling as an intermediary mechanism to transfer energy and signals between the moving belt sensors and the stationary external system without physical contact. This allows powered components to remain stationary while sensing elements stay embedded in the moving belt
2Use of energy by moving object
If on-belt batteries, storage capacitors, or energy-harvesting devices are used to power sensors, then sensor measurements can be made and transmitted, but the devices require recharging or replacement
Solution Approach 1:
The patent removes the power source from the moving belt system entirely, placing it in a stationary external system. This eliminates the finite operational duration problem of on-belt batteries and capacitors, as the stationary power source can operate continuously without being constrained by the belt's movement or replacement cycles
3Use of energy by moving object
If on-belt batteries, storage capacitors, or energy-harvesting devices are used to power sensors, then sensor measurements can be made and transmitted, but the devices take up space
Solution Approach 1:
The patent extracts all bulky power supply components from the belt structure and relocates them to stationary external units. This eliminates the space consumption problem by removing batteries, capacitors, and energy-harvesting devices from the confined space within the belt
4Use of energy by moving object
If on-belt batteries, storage capacitors, or energy-harvesting devices are used to power sensors, then sensor measurements can be made and transmitted, but the devices weaken the belt
Solution Approach 1:
The patent removes power supply devices from the belt structure, eliminating their weakening effect. The sensors remain as passive embedded elements without power sources attached, preserving the belt's structural integrity
Solution Approach 2:
The patent replaces the mechanical/physical power supply system (batteries, capacitors) with a magnetic field-based wireless power and signal transmission system. This substitution allows energy transfer without physical components that would compromise belt strength
5Measurement precision
If rip detectors with thin wire loops are used to detect belt tears, then binary detection can be made, but the devices are not designed to make a continuum of sensor measurements
Solution Approach 1:
The patent designs embedded sensors that serve multiple functions: they can detect binary conditions (such as belt tears) while also continuously measuring analog parameters (such as weight, temperature, or other physical quantities). The same sensor infrastructure supports both simple detection and continuous monitoring applications
Solution Approach 2:
The patent transitions from binary detection (torn/not torn) to continuous analog measurement by utilizing the same embedded sensor elements to detect varying degrees and types of conditions. The sensors can output continuous signals that reflect the magnitude and nature of detected parameters
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
Enables continuous, power-free monitoring of conveyor belt conditions, improving efficiency and reducing the weight and space requirements of existing solutions, while maintaining the integrity of the conveyor belt.
Implementation Method 1
Each of the resonant circuits has a resonant frequency and includes a sensing element sensing a condition affecting the conveyor belt and changing the resonant frequency as a function of the condition affecting the conveyor belt
Implementation Method 2
a coupling element connected to the sensing element... a stationary coupling element coacting with the coupling elements in the conveyor belt as they pass close to the stationary coupling element to couple the resonant circuits to the frequency detector
Data Source
Figure 1~2
Figure 3~5
Figure 6~8
AI summary
A conveyor and a sensing system for sensing various conditions on an advancing conveying bodies of a conveyor. The conveyor includes an array of sensing elements embedded in the conveying bodies to measure belt conditions. The sensing elements form parts of passive resonant circuits that each include a capacitor and an inductive coil. The capacitor or the inductive coil can be a sensing element. Measuring circuits external to the belt are inductively or capacitively coupled to the resonant circuits in the conveying bodies as they pass closely by. The sensing elements change the resonant frequency of their resonant circuits as a function of the sensed conditions. Frequency detectors in the measuring circuits measure that frequency change and convert it into a functionally related value used to determine a conveyor condition. Exemplary conditions include temperature, pressure, humidity, spillage, and product weight.