Magnetostrictive Sensor Alignment via Attenuation Element
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Solution Overview
Problem
Existing magnetostrictive sensors face challenges in accurately measuring stress due to small changes in magnetic permeability, which can result in measurement errors caused by varying gap distances between sensing elements and targets, requiring manual alignment that is prone to inconsistencies.
Innovation Solution
A sensor assembly with a magnetostrictive stress sensor and an attenuation element that allows for adjustable magnetic flux detection without axial translation, using a movable attenuation element or variable resistance to simulate gap adjustments, enabling precise alignment through yaw, pitch, and roll adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual alignment is used to set gap distance, then the sensor can be positioned relative to the target, but measurement errors occur due to inconsistent gap distances between sensing elements and target
Solution Approach 1:
The patent replaces manual mechanical alignment with an automated alignment system that uses magnetic field measurements to calculate and determine the optimal sensor orientation. The system automatically adjusts sensor orientation based on calculated alignment information, eliminating manual intervention and ensuring consistent, precise gap distances between sensing elements and the target.
Solution Approach 2:
The patent implements a feedback mechanism where the sensor measures magnetic field changes, the processor calculates alignment information based on these measurements, and the system automatically adjusts the sensor orientation accordingly. This closed-loop feedback ensures that the sensor achieves and maintains optimal alignment, resolving the inconsistency problem of manual alignment.
2Device complexity
If gap distance varies between sensing elements and target, then manual positioning is simpler, but measurement errors increase due to inconsistent magnetic flux detection
Solution Approach 1:
The patent replaces simple mechanical positioning with an automated electronic alignment system that uses magnetic field measurements and calculations to determine optimal sensor orientation. The processor analyzes magnetic flux measurements from multiple sensing elements and automatically calculates the orientation that equalizes gap distances, ensuring consistent measurement conditions without complex manual adjustment.
Solution Approach 2:
The patent changes the approach from mechanically controlling gap distance to electronically calculating and adjusting sensor orientation based on magnetic field parameters. By measuring magnetic flux variations and calculating optimal orientation angles, the system dynamically adjusts the sensor position to maintain equal gap distances, improving measurement precision while managing complexity through automation.
3Productivity
If the sensor is manually aligned with the target, then initial positioning is achieved, but alignment time increases due to iterative adjustments needed to equalize gap distances
Solution Approach 1:
The patent performs preliminary alignment by having the sensor initially positioned near the target, then using automated magnetic field measurements and calculations to determine the precise orientation. This preliminary positioning combined with automated calculation eliminates the need for iterative manual adjustments, significantly reducing alignment time while ensuring equal gap distances between sensing elements and the target.
Solution Approach 2:
The patent replaces time-consuming iterative manual alignment with a single-step automated process. The system takes initial magnetic field measurements, calculates the optimal orientation using processor-based algorithms, and automatically adjusts the sensor position in one operation, dramatically improving alignment speed and reducing the time loss associated with repeated manual adjustments.
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 approach allows for accurate stress measurement by maintaining a constant gap size between the sensor and target, reducing alignment time and improving measurement accuracy by ensuring equal changes in raw stress signals from detection elements.
Implementation Method 1
a drive element configured to generate a magnetic field having a corresponding magnetic flux that travels through a target
Implementation Method 2
an attenuation element that can be configured to allow the detected portion of the first magnetic flux to be selectively adjusted... The at least one conductive element can be configured to generate a second magnetic field that can interact with a portion of the first magnetic field, thereby adjusting a magnitude of the detected portion of the first magnetic flux
Implementation Method 3
Ferromagnetic materials can have magnetostrictive properties that can cause the materials to change shape in the presence of an applied magnetic field. The inverse can also be true. When a stress is applied to a conductive material, magnetic properties of the material, such as magnetic permeability, can change
Data Source
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Figure 2A
AI summary
Systems, methods, and devices for positioning, orienting, and/or aligning a stress sensor assembly are provided. Raw stress signals, which can correspond to stress in the target, can be generated by detecting a magnetic flux that travels through the target. The raw stress signals can be sensitive to an alignment of the sensor relative to the target. In order to minimize measurement error, the stress sensor can be properly aligned relative to the target prior to taking a stress measurement. Sensor alignment can involve adjusting a yaw, pitch, and/or roll of the sensor, measuring the raw stress signals, attenuating the detected magnetic flux, and measuring the raw stress signals again. When the stress sensor is properly aligned, a change in a size of a gap between the sensor and a surface of a target can result in approximately equal changes in the raw stress signal.