Split Piezo Sensor for Magnetostrictive Wire Position Measurement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing piezoelectric sensors used in magnetostrictive wire-based systems for liquid level and position measurement are labor-intensive to manufacture due to the need for precise machining of segmented piezo crystal elements, which complicates the assembly and increases production time.
Innovation Solution
A split sensor design is introduced, where two piezo crystals form an annular cylinder with a broken tubular sidewall, allowing for simplified assembly and reduced manufacturing complexity by eliminating the need for extensive hand labor, and using flexible conductors to accommodate the magnetostrictive wire without the need for precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If segmented piezo crystal elements are used in traditional piezoelectric sensors, then detection accuracy of torsional pulses is maintained, but manufacturing complexity and labor intensity increase significantly
Solution Approach 1:
The piezoelectric sensor is divided into multiple independently polarized segments arranged circumferentially around the magnetostrictive wire. Each segment can be polarized separately using simple planar electrodes, eliminating the need for complex circumferential electrode patterns while maintaining the ability to detect torsional pulses through the combined signal from all segments.
Solution Approach 2:
The invention changes the polarization configuration from a single circumferentially polarized crystal to multiple segments with individual polarization directions. By adjusting the polarization angle of each segment and their spatial arrangement, the sensor maintains detection accuracy while simplifying the manufacturing process through standard planar electrode techniques.
2Reliability
If traditional piezoelectric sensor assembly methods are used, then detection functionality is achieved, but assembly time and labor costs increase
Solution Approach 1:
The sensor assembly is segmented into modular piezoelectric elements that can be independently manufactured and then assembled around the magnetostrictive wire. This modular approach allows for parallel manufacturing and simplifies assembly procedures, directly addressing the productivity issue while maintaining detection reliability.
Solution Approach 2:
Instead of assembling complex circumferential electrode structures onto the piezoelectric crystal, the invention inverts the approach by placing simple planar electrodes on flat crystal surfaces and achieving circumferential sensing capability through the geometric arrangement of multiple segmented crystals around the wire.
3Measurement precision
If precise machining and alignment are required for piezoelectric sensor components, then measurement accuracy is maintained, but manufacturing time and costs increase
Solution Approach 1:
The invention changes the electrode geometry from complex circumferential patterns requiring precise alignment to simple planar electrodes on flat crystal surfaces. The measurement accuracy is maintained through the geometric arrangement and polarization configuration of multiple segments rather than through precise alignment of single-component features.
Solution Approach 2:
The invention inverts the traditional approach by not requiring precise circumferential alignment of electrodes on the crystal. Instead, it uses precisely controlled polarization directions of separately assembled crystal segments, where the alignment requirement is shifted from mechanical electrode positioning to controlled polarization application during manufacturing.
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 split sensor design significantly reduces manufacturing time and labor costs while maintaining accurate detection of torsional pulses, improving the efficiency and reliability of magnetostrictive position transducers.
Implementation Method 1
a piezoelectric sensor element comprising a piezoelectric material positioned to detect the torsional pulse
Implementation Method 2
a movable permanent magnet float or position indicator that surrounds a linearly oriented magnetostrictive wire... resulting in a torsional disturbance in the wire
Data Source
AI summary
A piezo sensor having an inner conductor having an inner conductor segment, where the inner conductor segment forms a tubular sidewall having a break, and also having an interior surface and an exterior surface; a plurality of individually polarized piezoelectric members, each having an inner face and an outer face, and each inner face contacting the first conductor exterior surface, each piezoelectric member being adjacent to another on the exterior face of the inner conductor, forming sets of adjacent faces; an outer conductor having an outer conductor segment forming a tubular sidewall having a break, the outer conductor having an interior surface and an exterior surface, where the interior surface contacts the outer face of the piezoelectric members; and where the break of the outer conductor segment is alignable with adjacent faces of two of the plurality of piezoelectric members, and further being alignable with the break of the inner conductor segment.