Strain Sensor Assembly Interference Fit Recess
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Strain sensors in industrial settings face challenges due to limited space, degradation from cyclic loads, corrosion, and environmental factors like moisture and temperature fluctuations, leading to reduced accuracy and the need for frequent replacements.
Innovation Solution
A strain sensor assembly with a support member and opposed strain gauge members that form an interference fit within a recess, allowing for compact design, reduced component count, and enhanced load detection without requiring voltage amplification, and enabling easy replacement by forming an electronic connection with the structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional strain sensors with multiple gauges and voltage amplifiers are used, then load detection capability is achieved, but device complexity and space requirements increase
Solution Approach 1:
The patent combines multiple strain gauge members and their support structures into a single integrated assembly that fits within a compact recess. The strain gauge members are mounted on a common support structure with shared wiring, merging multiple functions into one compact unit that eliminates the need for separate voltage amplifiers while maintaining load detection capability.
Solution Approach 2:
The strain sensor assembly is designed to be nested within a recess of the drill string component. The support member with strain gauge members is positioned within the recess, and the entire assembly fits into the existing structure, effectively nesting the sensor system within the drill string component to reduce overall device complexity and space requirements.
2Measurement precision
If strain sensors are placed in harsh environments with cyclic loads, then load detection is enabled, but reliability degrades over time due to corrosion and environmental factors
Solution Approach 1:
The strain gauge members are pre-biased against the recess wall, creating a predetermined compressive force that cushions the sensors against additional cyclic loading. This pre-biasing protects the strain gauges from excessive stress during operation, preventing damage from cyclic loads and improving reliability in harsh drilling environments.
Solution Approach 2:
The strain gauge members are designed with flexible biasing portions that can elastically deform to accommodate cyclic loading while maintaining contact with the recess wall. This flexibility allows the sensors to withstand repeated stress cycles without permanent deformation or failure, enhancing durability in harsh environments.
3Measurement precision
If strain sensors require voltage amplifiers and extensive wiring, then measurement capability is improved, but ease of operation and replacement is reduced
Solution Approach 1:
The strain sensor assembly is segmented into a self-contained unit with integrated strain gauge members, support structure, and wiring. This modular design allows the entire sensor assembly to be replaced as a single component without disturbing the drill string component or other sensors, significantly improving ease of replacement while maintaining full measurement capability.
Solution Approach 2:
The voltage amplifier function is extracted from the sensor design itself and replaced with a direct resistance measurement approach. The strain gauge members are configured to provide measurable resistance changes directly, eliminating the need for separate voltage amplification circuitry and reducing the complexity of installation and replacement operations.
4Measurement precision
If more strain gauge members are added to improve measurement accuracy, then measurement precision improves, but the space required and device complexity increase
Solution Approach 1:
The strain gauge members are arranged in a radial pattern around the recess, utilizing the circumferential dimension rather than only linear spacing. This radial configuration allows multiple strain gauges to be positioned within the limited cross-sectional area of the recess, improving measurement accuracy through multiple sensing elements without increasing the overall space footprint.
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 strain sensor assembly provides accurate load detection and measurement in harsh environments with reduced noise and the ability to maintain performance over time, eliminating the need for voltage amplifiers and facilitating easy replacement, thus addressing space and durability limitations.
Implementation Method 1
When a load is applied to the strain sensor, deformation of the strain gauge cause an alternation in resistance across the circuit that is proportional to the load applied to the strain sensor
Implementation Method 2
The biasing portion is configured to bias against a wall of the recess of the drill string when the strain sensor is disposed in the recess
Data Source
AI summary
A strain sensor assembly is configured to detect one or more of forces applied to a structure having a recess. The strain sensor can include at least a pair of opposed strain gauge members that extend from the support member. Each strain gauge member defines a support portion carried by the support member and a biasing portion. The support portion includes at least one strain gauge sensor. The biasing portion is configured to bias against a wall of the recess of the structure when the strain sensor assembly is disposed in the recess. The strain sensor assembly is configured such that the at least a pair of strain gauge members form an interference fit with the wall of the recess when the strain sensor assembly is inserted in the recess.