Tensioned Wire Ultrasonic Sensor for Harsh Environments
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Solution Overview
Problem
Conventional sensors used in harsh environments, such as aero gas turbine engines, fail frequently due to material limitations and the challenges of bonding dissimilar materials, leading to high maintenance costs and inaccurate measurements.
Innovation Solution
A sensor design that utilizes a housing, diaphragm, and wires made from suitable materials like stainless steel and titanium alloys, where ultrasonic signals are transmitted through wires to measure environmental conditions like pressure and temperature, allowing for remote equipment placement while accurately sensing conditions at the desired location.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional sensors are used in harsh environments, then material limitations and bonding challenges arise, but sensor reliability improves
Solution Approach 1:
The patent applies homogeneity by constructing the sensor from a single material (stainless steel or titanium alloy) throughout the entire structure, including the housing, diaphragm, and wires. This eliminates the need to bond dissimilar materials, thereby removing the complexity and reliability issues associated with material interfaces while maintaining sensor functionality in harsh environments.
2Duration of action of stationary object
If conventional sensors are used in harsh environments, then sensor lifetime is limited, but maintenance costs increase
Solution Approach 1:
By using a single material construction, the sensor eliminates the weakness of material interfaces that typically limit sensor lifetime in harsh environments. The uniform material structure provides consistent performance and durability, extending sensor operational life and reducing maintenance requirements.
3Measurement precision
If sensors are placed remotely from the desired sensing location, then measurement accuracy improves, but device complexity increases
Solution Approach 1:
The patent applies segmentation by separating the sensing element (diaphragm) from the signal processing and power supply components. The diaphragm is positioned at the desired sensing location to accurately measure environmental conditions, while the wires transmit signals to remote evaluation equipment. This allows the sensor to be configured with minimal complexity while achieving both accurate measurement and remote operation.
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 sensor effectively measures environmental conditions in harsh environments with improved reliability and reduced maintenance costs by using a single material construction and ultrasonic signal transmission, overcoming material limitations and bonding challenges.
Implementation Method 1
The wire may exhibit varying ultrasonic signal transmission characteristics as the tension between the wire and the diaphragm changes
Data Source
AI summary
Systems and methods for measuring environmental conditions of a sensing location, where a sensor including a measuring surface and a wire coupled in tension to the measuring surface over which ultrasonic signals may be transmitted and sensed. Signal analysis of ultrasonic signals transmitted over the tensioned wire are analyzed to measure one or more environmental conditions acting on the measuring surface.