Passive Wireless Sensor Subsystem for Turbomachine Rotors
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Solution Overview
Problem
Existing turbomachines face challenges with sensing devices that require extensive wiring and complex configurations due to rotational operations, leading to high construction and maintenance costs, and post-manufacture affixing of sensors may not fully integrate with rotatable components, limiting their effectiveness and positioning.
Innovation Solution
A monitoring system integrated into turbomachines with a sensor subsystem and dielectric layer on rotatable components, using a passive wireless sensing method that regulates electromagnetic fields to measure characteristics, eliminating the need for extensive wiring and allowing for in-manufacture integration of sensors with components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If known sensing devices are coupled to rotatable components (compressor blades, turbine buckets), then measurement data can be transmitted, but extensive wiring and complex slip ring configurations are required, increasing construction and maintenance costs
Solution Approach 1:
The patent replaces mechanical wiring and slip ring configurations with a wireless sensing system. The sensor subsystem includes a sensor electromagnetic structure that communicates wirelessly with a reader subsystem, eliminating the need for physical connections to rotating components. This substitution resolves the technical contradiction by maintaining measurement data transmission reliability while dramatically reducing device complexity associated with wiring and slip rings.
Solution Approach 2:
The patent extracts the sensor components from the traditional wired configuration and implements them as a separate wireless sensor subsystem that can be integrated into rotatable components during manufacturing. The sensor electromagnetic structure and reader subsystem communicate through electromagnetic fields rather than physical connections, removing the harmful wiring complexity while preserving measurement capabilities.
2Device complexity
If wireless sensing devices are deposited on or formed in layers on rotatable components, then wiring complexity is reduced, but post-manufacture affixing may not fully integrate sensors with components, limiting effectiveness
Solution Approach 1:
The patent applies preliminary action by integrating the sensor subsystem into rotatable components during the manufacturing process rather than as a post-manufacture addition. The sensor electromagnetic structure is incorporated into the component design from the outset, ensuring full integration and optimal performance. This preliminary integration resolves the contradiction by maintaining low wiring complexity while achieving reliable sensor-component integration through advance planning and manufacturing integration.
3Measurement precision
If known sensing devices are used on rotatable components, then measurement can be obtained, but they can withstand high temperatures and stresses for only a short period of time (100 hours or less)
Solution Approach 1:
The patent employs composite materials by incorporating the sensor electromagnetic structure within a protective dielectric layer that is formed over the sensor components. This protective layer shields the sensor from harsh environmental conditions including high temperatures and stresses, enabling extended operational duration while maintaining measurement precision. The composite structure of sensor plus protective dielectric layer resolves the contradiction between measurement capability and operational durability.
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
This solution reduces preparation time and resources for turbomachines, enhances sensor integration, increases security against non-OEM duplication, and positions sensors optimally, enabling robust and efficient monitoring in harsh environments.
Implementation Method 1
The sensor electromagnetic structure is configured to regulate electromagnetic fields incident thereto in response to at least one measurement characteristic of a machine measurand
Implementation Method 2
generating, with a reader subsystem, an electromagnetic field proximate a sensor subsystem, thereby illuminating a sensor conducting subcomponent with the electromagnetic field
Data Source
AI summary
A machine includes a machine substrate and a dielectric layer formed over at least a portion of the machine substrate. A monitoring system for the machine includes a sensor subsystem that includes a first portion of the machine substrate and a portion of the machine dielectric layer formed over the first portion of the machine substrate. The monitoring system also includes a sensor electromagnetic structure disposed on the portion of the machine dielectric layer. The sensor electromagnetic structure includes at least one sensor conducting subcomponent. The sensor electromagnetic structure is configured to regulate electromagnetic fields incident thereto in response to at least one measurement characteristic of a machine measurand. The sensor subsystem is configured to obtain at least one measurement characteristic of the machine measurand proximate a machine sensing position.