Wireless Lubricant Sensing With Capacitance Isolation
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Solution Overview
Problem
Conventional methods for monitoring the lubricant level and quality in industrial machines, such as gear trains, are limited by their practicality, especially in harsh environments and space-constrained applications, and often require wired connections, which are not suitable for all machines.
Innovation Solution
A wireless sensing system that includes a sensor coupled with a processor and transmitter, capable of wirelessly communicating data signals to a remote reader, which detects fluid levels and quality in gear cases, and can isolate sensor capacitance, allowing for real-time monitoring and operational planning to prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If wired sensors are used to monitor lubricant levels and quality, then measurement precision can be maintained, but device complexity and installation difficulty increase due to wiring requirements in harsh environments
Solution Approach 1:
The patent replaces wired mechanical/electrical connections with wireless communication technology. The sensor system uses wireless transmitters to communicate lubricant level and quality data to receivers, eliminating the need for physical wiring in harsh environments while maintaining measurement precision through capacitive sensing and wireless data transmission.
Solution Approach 2:
The patent introduces wireless communication as an intermediary between the sensor and the monitoring system. The wireless transmitter acts as a mediator that transfers data without direct physical connection, solving the wiring complexity problem while preserving measurement accuracy through the use of capacitive sensors and wireless protocols.
2Ease of operation
If wireless sensors are used to simplify installation, then ease of operation improves, but reliability may deteriorate due to potential wireless communication failures
Solution Approach 1:
The patent implements feedback mechanisms where the wireless sensor system continuously monitors lubricant conditions and transmits data back to the monitoring system. This closed-loop feedback ensures reliable operation by maintaining continuous communication and allowing for real-time detection and correction of any communication or measurement issues.
Solution Approach 2:
The patent employs redundant communication protocols and error correction mechanisms as preventive measures. By building in these cushioning elements beforehand, the system can withstand potential wireless communication failures and maintain reliability even in harsh electromagnetic environments.
3Reliability
If continuous monitoring is implemented to prevent machine damage, then reliability improves, but energy consumption increases
Solution Approach 1:
The patent uses periodic monitoring instead of truly continuous monitoring. The wireless sensor system takes measurements at predetermined intervals and transmits data periodically, which maintains machine protection capability while significantly reducing energy consumption compared to continuous real-time monitoring.
Solution Approach 2:
The patent implements self-powered or energy-harvesting sensor capabilities where the sensor uses minimal energy from the machine's operation or harvests energy from the environment. This self-service approach enables continuous monitoring functionality while maintaining low overall energy consumption through efficient power management.
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
Enables effective monitoring of lubricant levels and quality in industrial machines, allowing for timely maintenance and operational adjustments to prevent damage, even in harsh environments and space-constrained applications, improving machine reliability and efficiency.
Implementation Method 1
The sensor is configured to contact a fluid and measure a characteristic of the fluid... The one or more processors are configured to detect a level of the fluid based at least in part on the capacitance that is measured
Data Source
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AI summary
A system includes a sensor, one or more processors, a transmitter, and a capacitance control structure. The sensor is configured to contact a fluid and measure a characteristic of the fluid. The one or more processors are operably coupled to the sensor. The one or more processors are configured to generate one or more data signals representative of the characteristic of the fluid that is measured by the sensor. The transmitter is operably coupled to the one or more processors. The transmitter is configured to wirelessly communicate the one or more data signals to a remote reader. The capacitance control structure is configured to one or more of reduce or isolate sensor capacitance of the sensor 108 from the one or more processors.