Strain Sensor Placement on Nonplanar Geometries
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Solution Overview
Problem
Conventional strain sensors struggle to accurately measure strain on components with nonlinear and nonplanar geometries due to nonuniform strain fields and low strain transfer ratios, resulting in inaccurate readings.
Innovation Solution
A method and system that determine the preferred placement, feature dimension, and orientation of strain sensors on components using iterative computer analysis and aerosol-based direct-write printing with chromium-containing alloy particles, ensuring optimal strain transfer and accurate strain measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional strain sensors with predetermined shape and size are used, then manufacturing is simplified, but measurement precision deteriorates due to inability to capture focused strain gradients on nonlinear and nonplanar geometries
Solution Approach 1:
The patent applies local quality by customizing the strain sensor's shape, size, and orientation to match the specific local strain field characteristics at the measurement location. The sensor geometry is tailored to the local curvature and strain gradient of the component surface, enabling accurate measurement of focused strain gradients while maintaining manufacturability through direct digital synthesis manufacturing processes.
2Measurement precision
If strain sensors are placed on nonlinear and nonplanar geometries, then measurement coverage is improved, but strain transfer ratio deteriorates due to geometric mismatch
Solution Approach 1:
The patent applies preliminary action by performing iterative computer analysis and finite element modeling before manufacturing to determine the optimal sensor placement, shape, size, and orientation. This pre-planning ensures the sensor is designed to match the component's geometry and strain field characteristics, maximizing strain transfer ratio while simplifying the actual manufacturing and placement process through direct digital synthesis.
3Adaptability or versatility
If conventional strain sensors with fixed geometry are used, then device complexity is reduced, but adaptability deteriorates for different component geometries and strain fields
Solution Approach 1:
The patent applies parameter changes by systematically varying the sensor's geometric parameters (shape, size, orientation, and placement location) based on the specific component geometry and strain field characteristics. The iterative computer analysis evaluates multiple parameter combinations to identify the optimal configuration, enabling the sensor to adapt to different component geometries while managing design complexity through automated optimization processes.
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 solution enables precise strain measurement on components with complex geometries by customizing strain sensor placement and design, improving accuracy and consistency of strain readings.
Implementation Method 1
printing the strain sensor at the preferred placement on the component with the preferred feature dimension and orientation
Implementation Method 2
aerosol-based direct-write printing with chromium-containing alloy particles
Data Source
AI summary
A method for measuring strain of a component includes determining a preferred placement for a strain sensor on the component, and a preferred feature dimension and orientation for the strain sensor at the preferred placement on the component; and printing the strain sensor at the preferred placement on the component with the preferred feature dimension and orientation.