Embedded Sensor Foil Bearing for Low-Uncertainty Diagnostics
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
External sensors on foil bearings increase measurement uncertainty and form factor due to the need for maintenance and distance from environment conditions, leading to additional costs.
Innovation Solution
Integration of conductive sensor sections within the foil bearing, including thermocouples, speed sensors, and acceleration sensors, with distinct metallic conductor materials and insulators, embedded throughout the foil's circumference to reduce uncertainty and eliminate external sensory components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If external sensors are used on foil bearings, then diagnostic information can be obtained, but measurement uncertainty increases and form factor increases
Solution Approach 1:
The patent combines the sensor functionality with the foil bearing structure itself by embedding conductive material compositions within the foil layers. This integration eliminates separate external sensors, reducing form factor and measurement uncertainty while maintaining diagnostic capabilities through embedded temperature, speed, and acceleration sensors.
Solution Approach 2:
The sensor sections are nested within the multi-layered foil structure, with conductive material compositions embedded between body material layers. This nesting approach allows sensors to be contained within the bearing assembly without increasing external dimensions, resolving the contradiction between diagnostic capability and form factor.
2Reliability
If external sensors are fastened to bearing assemblies, then diagnostic information can be obtained, but maintenance requirements increase
Solution Approach 1:
By merging sensor functionality with the foil bearing structure through embedded conductive material compositions, the patent eliminates separate external sensors that would require independent maintenance. The integrated sensors become part of the bearing assembly, reducing maintenance requirements while maintaining diagnostic reliability.
Solution Approach 2:
The embedded sensors within the foil structure provide self-monitoring capabilities without requiring external attachment or separate maintenance systems. The sensors are inherently part of the bearing assembly, enabling self-diagnosis and reducing the need for external maintenance interventions.
3Loss of information
If external sensors are positioned at a distance from the bearing, then diagnostic information can be obtained, but costs increase
Solution Approach 1:
The patent merges sensors with the foil bearing structure through embedded conductive material compositions, eliminating the need for external sensors positioned at a distance. This integration reduces costs by eliminating additional components, installation requirements, and potential measurement errors associated with distance-based sensing, while maintaining complete diagnostic information.
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
Enhances diagnostic capabilities by embedding sensors within the foil bearing, reducing uncertainty and costs associated with external sensors, while maintaining the low conductivity of the body material, thus ensuring efficient operation and reduced maintenance.
Implementation Method 1
The conductive material composition includes a first metallic conductor material disposed distinctly from a second conductor material joined to form a thermocouple of the sensor section about the circumferential portion
Implementation Method 2
the sensor section forms an acceleration sensor configured to generate a voltage from forces imparted on the conductive material composition
Implementation Method 3
the sensor section forms a speed sensor configured to conduct current induced from magnetic fields
Data Source
Figure 1~2A
Figure 2B
Figure 3A~3B
AI summary
Disclosed is a foil bearing (100) that includes a housing (102), a support structure (104) associated with the housing, and a foil (106) circumscribed at least in part by the support structure and spaced from the housing by the support structure. The foil includes a body section (108) having a body material composition. The foil includes a sensor section having a conductive material composition, the sensor section (110,118,122) having a circumferential portion surrounded at least in part by the body section. The foil includes a tab section (126) that protrudes into the support structure and defines a first terminal and a second terminal associated with the sensor section.