Tamperproof Ultrasonic Sensor With Frangible Circuit
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Solution Overview
Problem
Conventional ultrasound sensors face challenges in industrial non-destructive testing due to instability, operator errors, temperature limitations, and difficulty in monitoring complex or hard-to-reach objects, leading to inaccurate data and operational inefficiencies.
Innovation Solution
A tamperproof ultrasonic sensor with a piezoelectric element and frangible components that ensures irreversible inoperability upon removal, allowing for flexible mounting and operation across a wide temperature range without the need for adhesives or permanent installation, using a compressive force to establish and break the electrical circuit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional ultrasound sensors are used for long-term monitoring, then measurement stability deteriorates due to sensor disturbance or damage, but the sensor can be physically disturbed without stopping its function
Solution Approach 1:
The patent applies preliminary action by pre-configuring the sensor with a frangible component that will break upon removal attempts. This preventive measure is built into the sensor design before deployment, so that any unauthorized removal or disturbance automatically triggers the inoperable state through the breaking of the electrical circuit, eliminating the need for continuous monitoring or intervention to detect tampering.
Solution Approach 2:
The patent employs the disposable principle by designing the sensor with a frangible component intended to break after a single use or upon removal. The sensor is deliberately made non-reusable - once the frangible component breaks and the circuit opens, the sensor cannot be restored to operational state. This ensures measurement integrity by preventing reuse of removed sensors, though it requires replacement of the sensor rather than repair.
2Power
If traditional piezoelectric materials (ceramics and polymers) are used in ultrasound sensors, then the sensors can convert electrical energy to mechanical energy effectively, but they lose efficiency at high temperatures above their curie temperature or through de-poling at around 100°C
Solution Approach 1:
The patent applies parameter changes by transitioning from traditional piezoelectric materials (ceramics and polymers) to a novel piezoelectric material composition that maintains its piezoelectric properties at elevated temperatures. This material parameter change enables the sensor to operate reliably in high-temperature environments (above 100°C and potentially above the curie temperature of traditional materials) without losing efficiency through de-poling or phase transitions.
Solution Approach 2:
The patent employs composite materials by using a piezoelectric material that may combine multiple components or phases to achieve high-temperature stability. This composite approach allows the material to maintain its piezoelectric properties at temperatures where traditional single-phase ceramics or polymers would fail, providing both the necessary electrical-to-mechanical energy conversion and thermal resilience.
3Adaptability or versatility
If ultrasound sensors are mounted on non-flat objects, then the sensor can monitor complex geometries, but variations in sensor angle relative to the object surface cause large amounts of operator error
Solution Approach 1:
The patent applies the dynamics principle by making the sensor mounting system adaptable and flexible rather than fixed and rigid. The sensor can dynamically adjust its orientation and contact pressure to conform to the local surface geometry of non-flat objects. This dynamic adaptation ensures that the sensor maintains optimal acoustic coupling and perpendicular alignment with the surface regardless of the object's shape, eliminating operator error from incorrect angle positioning.
Solution Approach 2:
The patent employs flexible shells and thin films in the sensor mounting interface, allowing the sensor to conform to curved or irregular surfaces. This flexibility enables the sensor to maintain consistent acoustic contact and proper orientation on non-flat objects without requiring precise manual alignment, thereby preserving measurement precision while achieving adaptability to complex geometries.
4Ease of operation
If conventional ultrasound sensors are used in hard-to-reach locations, then measurements can be taken during normal operating conditions, but the time available for measurements is limited and operator error increases due to repeated measurements weeks or months apart
Solution Approach 1:
The patent applies the self-service principle by enabling the sensor to be permanently installed in hard-to-reach locations where it can autonomously perform continuous monitoring without requiring repeated human intervention. Once installed, the sensor independently collects measurement data over extended periods, eliminating the need for operators to periodically access difficult locations and reducing both time loss and operator error associated with repeated manual measurements.
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 provides stable, accurate, and long-term monitoring of objects with reduced operator errors and increased reliability, enabling continuous data collection in harsh environments without the need for repeated calibrations or manual intervention.
Implementation Method 1
an ultrasound transducer comprising: a piezoelectric element; and an active electrode and a counter electrode adapted for electrical connection to the piezoelectric element
Data Source
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AI summary
An ultrasonic sensor comprising an ultrasonic transducer, the ultrasonic transducer comprising: a piezoelectric element; and an active electrode and a counter electrode adapted for electrical connection to the piezoelectric element; wherein the piezoelectric element, the active electrode and the counter electrode are comprised in at least part of an electrical circuit for operating the piezoelectric element; the ultrasonic sensor is mounted or configured to be mountable to an entity to be sensed; and the ultrasonic sensor is adapted such that removal of the ultrasonic sensor from the entity causes a breaking of an electrical circuit so as to render the ultrasonic sensor inoperable or irreversibly inoperable.