Sensor Leakage Tester Using High-Impedance Voltage Divider
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Solution Overview
Problem
Existing methods for detecting electrical current leakage in sensor systems, such as those used on vehicles, are ineffective due to contamination from substances like hydraulic fluid and metal particles, which corrupt sensor signals and are difficult to detect with conventional multimeters or high-voltage testers that are expensive, bulky, and damaging.
Innovation Solution
A hand-held, battery-powered sensor leakage tester that applies a DC voltage through a high-impedance resistor to detect electrical leakage between sensor pins and the connector shell, using a voltage divider to measure leakage and determine the presence of contaminants without risking damage to the sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a common multimeter is used to test continuity between sensor wires and connector shell, then the testing method is simple and inexpensive, but the low voltage (less than one volt) is not sufficient to measure continuity through contaminant
Solution Approach 1:
The patent changes the voltage parameter from less than one volt (multimeter) to a higher voltage level that is sufficient to ionize and conduct through contaminant, while still being low enough to avoid damaging sensor electronics. This parameter adjustment enables the detection of contamination that was previously undetectable.
Solution Approach 2:
The patent introduces a specialized leakage tester as an intermediary device between the multimeter and hi-pot tester. This device uses a voltage divider circuit with high-impedance resistors to create an intermediate testing voltage level that can detect contamination without damaging sensors, bridging the gap between the insufficient multimeter voltage and the damaging hi-pot voltage.
2Measurement precision
If hi-pot testers are used to test wiring and connectors, then continuity through contaminant can be detected, but the testers are very expensive, bulky, and damaging to sensitive electronics inside sensors
Solution Approach 1:
The patent adjusts the voltage parameter to a specific range that is high enough to ionize contaminant and enable conductivity measurement, but low enough to prevent breakdown of sensor electronics. This optimized voltage parameter achieves contamination detection without the damaging effects of high-voltage hi-pot testers.
Solution Approach 2:
The patent introduces a voltage divider circuit with high-impedance resistors as an intermediary mechanism that limits the current and voltage applied to the sensor. This intermediary structure allows the use of higher testing voltages without directly exposing the sensitive sensor electronics to damaging voltage levels.
3Ease of manufacture
If individual wires are checked one at a time with a multimeter, then the testing method is simple, but the process is very time consuming when there are dozens of sensors and multiple wires
Solution Approach 1:
The patent combines multiple wire testing operations into a single integrated testing process. The leakage tester is configured to simultaneously test multiple sensor wires and their connections to the connector shell, merging what would otherwise require multiple separate multimeter measurements into one efficient operation.
Solution Approach 2:
The patent creates a universal testing device that can test multiple different sensor types and wiring configurations through a single interface. The leakage tester is designed to handle various sensor arrangements and connector types, eliminating the need for separate testing procedures for each individual wire or sensor.
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 quick and effective detection of electrical leakage in sensor systems, allowing for rapid identification and remediation of contaminated sensors, reducing testing time from hours to minutes and avoiding damage to sensitive electronics.
Implementation Method 1
using a voltage divider to measure leakage and determine the presence of contaminants
Data Source
AI summary
A test system for testing a sensor system includes a high-impedance resistor for forming a voltage divider with any corrosion or foreign substance that might be present between a signal conductor and a ground conductor. While a voltage is applied across the voltage divider, the voltage can be measured across the high-impedance resistor for determining whether an undesirable amount of conductance exists between the signal wire and ground. The test system also includes switching means for switching between any number of signal wires of a system undergoing testing.