Resonant Sensor Probe Assembly with Free-Standing Electrodes
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Solution Overview
Problem
Current sensor technologies for monitoring oil conditions in engines and transformers face limitations such as low sensitivity and inability to accurately detect leaks and fluid impurities due to substrate-based electrode designs, which restrict early diagnosis and long-term reliability.
Innovation Solution
A resonant sensor probe assembly with free-standing electrodes, formed from dielectric materials, that generates an electric field and measures impedance responses without a substrate, enhancing sensitivity and selectivity by allowing larger electrode contact areas and improved fluid flow, and incorporates additive manufacturing for precise fabrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional substrate-based electrode sensors are used, then the sensor structure is simple to manufacture, but the sensitivity and resolution for detecting fluid impurities are low
Solution Approach 1:
The patent extracts the electrodes from the substrate support structure, creating free-standing electrodes that can be positioned independently in the fluid. This extraction allows the electrodes to have larger surface area contact with the fluid and eliminates substrate interference, thereby improving detection sensitivity while the electrodes remain electrically connected to the measurement circuitry
Solution Approach 2:
The patent transitions from two-dimensional electrode patterns on a substrate to three-dimensional free-standing electrode structures. This dimensional change allows the electrodes to extend into the fluid more effectively, increasing the active sensing volume and improving detection precision without requiring a complex substrate-based layout
2Area of stationary object
If substrate-based electrode designs are used, then manufacturing is easier, but the electrode contact area with fluid is restricted
Solution Approach 1:
The electrodes are extracted from the substrate and made free-standing, allowing them to achieve maximum contact area with the fluid. The electrodes can be positioned optimally in the fluid flow path without being constrained by substrate geometry, thereby increasing the effective sensing area
Solution Approach 2:
The free-standing electrodes are nested within a support structure that provides mechanical stability without interfering with the electrode-fluid interface. This nesting arrangement allows the electrodes to maintain large contact area while the support structure simplifies the overall manufacturing process
3Measurement precision
If conventional DGA systems with gas extraction are used, then gas concentration can be measured, but the system becomes expensive and complex with many moving parts
Solution Approach 1:
The patent extracts the measurement function directly into the oil-immersed sensor, eliminating the need for separate gas extraction systems. The free-standing electrodes measure impedance changes caused by dissolved gases and impurities directly in the oil, removing complex gas handling equipment while maintaining measurement precision
Solution Approach 2:
The patent uses impedance measurement as an intermediary method to detect dissolved gases and impurities. Instead of directly analyzing gas phases, the sensor measures electrical impedance changes in the oil caused by the presence of contaminants, providing an indirect but effective measurement approach that simplifies the overall system
4Reliability
If conventional sensors are used for long-term monitoring, then initial measurements are accurate, but sensor drift occurs over time
Solution Approach 1:
The free-standing electrode design with optimized fluid flow characteristics enables the sensor to maintain stable measurements over time. The design minimizes fouling and degradation by allowing continuous fluid circulation around the electrodes, and the sensor can be automatically cleaned or recalibrated without removing it from the system
Solution Approach 2:
The patent optimizes the electrical and geometric parameters of the free-standing electrodes to minimize drift. By carefully selecting electrode materials, dimensions, and spacing, the sensor achieves stable impedance characteristics that resist degradation over time, extending reliable operation
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 improved sensitivity and selectivity in monitoring oil conditions, enabling early detection of leaks and impurities, and extends sensor lifespan through automated aging correction, ensuring accurate long-term monitoring.
Implementation Method 1
The controller may control generation of an electric field between the free-standing electrodes and determine an impedance response of the sensor probe assembly to a fluid between the electrodes responsive to generation of the electric field between the free-standing electrodes
Implementation Method 2
determine an impedance response of the sensor probe assembly to a fluid between the electrodes
Data Source
AI summary
A resonant sensor probe assembly includes a substrate formed from one or more dielectric materials and free-standing electrodes coupled with the substrate. The free-standing electrodes are configured to be placed into the fluid and to generate an electric field between the free-standing electrodes. A controller measures an impedance response of the sensor to the fluid between the electrodes to determine an aging effect of the sensor.