Rotary Joint Wireless Sensor Assembly
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Solution Overview
Problem
Current assemblies for acquiring operational data from machines with power generating devices and rotating components are limited in their ability to wirelessly monitor various types of data, such as torque, RPM, horsepower, acceleration, temperature, and strain, while also needing improvements for increased fuel economy, longer vehicle life, and compactness with protection from ambient forces.
Innovation Solution
A wireless sensor assembly that includes sensors for measuring operational data and a microprocessor for interpretation, integrated with a power generating device and rotating component, utilizing inductive energy harvesting for power and featuring a pre-calibrated torque joint instrument for real-time data transmission, including air density corrections for accurate horsepower measurement, and early failure detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor assembly is integrated with a rotating component for wireless monitoring of operational data, then measurement capability is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple sensors (strain gauges, temperature sensors, accelerometers) and a microprocessor into a single integrated sensor assembly that attaches to the rotating component. This merging approach enables comprehensive operational data monitoring (torque, temperature, vibration, RPM) while managing complexity through modular integration rather than separate systems.
Solution Approach 2:
The sensor assembly acts as an intermediary between the rotating component and the data analysis system. It collects, processes, and transmits operational data wirelessly, serving as a mediator that simplifies the overall system architecture by consolidating sensing, processing, and communication functions in one unit.
2Use of energy by moving object
If inductive energy harvesting is used to power the sensor assembly, then energy independence is improved, but use of energy increases due to additional harvesting components
Solution Approach 1:
The sensor assembly employs inductive energy harvesting to power itself, eliminating the need for external battery replacement or wiring to the primary battery system. The harvesting components (coils or capacitors) capture electromagnetic energy from the rotating component's magnetic field or from ambient sources, enabling the sensor assembly to be self-powered and energy-independent.
3Manufacturing precision
If pre-calibrated torque joint instrument is used, then manufacturing precision is improved, but ease of manufacture decreases due to calibration requirements
Solution Approach 1:
The torque joint instrument is pre-calibrated during manufacturing to establish accurate measurement baselines. This preliminary calibration action ensures measurement precision is built into the component before installation, eliminating the need for field calibration and reducing installation complexity despite the added manufacturing step.
4Reliability
If sensor assembly is protected from ambient forces, then reliability is improved, but device complexity increases due to protective structures
Solution Approach 1:
The sensor assembly is enclosed in a protective housing or shell that shields sensitive components from ambient forces, moisture, and contamination. This protective structure is designed to be integrated with the rotating component, providing reliability through environmental protection while minimizing added complexity through streamlined design.
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 comprehensive real-time monitoring of operational data, improving fuel efficiency and extending vehicle life by providing accurate and reliable data transmission without the need for primary battery connection, while being protected from external forces and capable of early failure detection.
Implementation Method 1
The sensor assembly includes an inductive energy harvesting assembly having an inductive ring for harvesting ambient energy from the rotating component to provide power to the sensor assembly
Data Source
AI summary
The aspects of the present disclosure provide an assembly for acquiring operational data from a machine including a power generating device and a rotating component interconnected with the power generating device for transmitting power from the power generating device. The assembly may include a sensor assembly having a-sensor being interconnected to the rotating component for sensing operational data of the machine and a microprocessor communicatively connected to the sensor for receiving and interpreting the operational data sensed by the sensor.