Wireless NDT Sensor With Wide Enclosure Coil
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Solution Overview
Problem
Existing wireless non-destructive testing (NDT) sensors are large, heavy, and complex in design, making them challenging to integrate into test objects like composite aircraft panels and gas-turbine engine components, and they face issues with inductive coupling due to eddy currents generated by the transmitting coil.
Innovation Solution
A wireless NDT sensor design featuring a transducer coil with an open centre enclosure that is wider than the transducer, allowing for inductive operation without a ferrite core, resulting in a lighter and more compact sensor. This design includes a flexible electromagnetic interference (EMI) absorber to mitigate eddy currents on metallic structures, enabling efficient coupling and a low profile for embedded applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a wireless NDT sensor is designed with traditional inductive coupling, then power can be provided from an external device, but the sensor becomes large, heavy and complex
Solution Approach 1:
The patent employs a thin ferrite layer (0.1-1mm thick) instead of bulky magnetic shielding materials, achieving magnetic field management in a compact form factor. This thin film approach enables wireless operation while keeping the sensor compact and simple in design
Solution Approach 2:
The patent optimizes the ferrite layer parameters (thickness, permeability, conductivity) to achieve effective magnetic shielding with minimal material. By changing these physical parameters, the sensor achieves wireless capability without becoming large or complex
2Reliability
If ferrite material is used to manage magnetic field, then inductive coupling is improved, but the sensor weight and size increase
Solution Approach 1:
The patent uses a thin ferrite layer (0.1-1mm) instead of thick magnetic shielding materials, dramatically reducing the weight while maintaining effective magnetic field management and inductive coupling efficiency
Solution Approach 2:
The patent combines ferrite material with non-magnetic support structures and bonding layers, creating a composite assembly where the ferrite provides magnetic functionality while the other materials provide structural support, thereby reducing overall weight
3Reliability
If ferrite material is used to manage magnetic field, then inductive coupling is improved, but the sensor dimensions increase
Solution Approach 1:
The patent employs a thin ferrite layer (0.1-1mm thick) that provides effective magnetic field management in a minimal volume, allowing the sensor to maintain compact dimensions while achieving reliable inductive coupling
Solution Approach 2:
The patent transitions from volumetric magnetic shielding to a planar thin-film approach, concentrating the magnetic field management function in a two-dimensional layer that minimizes the third dimension (thickness), thereby reducing overall sensor volume
4Volume of moving object
If the transducer coil enclosure is sized to the transducer, then compactness is achieved, but eddy currents interfere with inductive coupling
Solution Approach 1:
The patent introduces a ferrite layer as an intermediary between the transducer coil and the test object. This ferrite layer acts as a mediator that guides magnetic flux and suppresses eddy currents, enabling compact sensor design without harmful electromagnetic interference
Solution Approach 2:
The patent converts the potentially harmful eddy currents into beneficial magnetic flux guidance by using the ferrite layer to channel and control the electromagnetic fields, transforming the interference problem into improved coupling efficiency
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 a compact, lightweight, and simpler NDT sensor with improved inductive coupling, suitable for embedded applications, especially in composite materials and metallic structures, allowing for efficient property evaluation with reduced structural impact.
Implementation Method 1
an electrically conductive transducer coil configured to define an enclosure and being electrically coupled to the transducer to enable the transducer to be inductively operated by a remote device
Implementation Method 2
This design includes a flexible electromagnetic interference (EMI) absorber to mitigate eddy currents on metallic structures
Data Source
AI summary
This application relates to a wireless sensor (10) suitable for non-destructive testing of a test object. The sensor comprises a transducer (12) and an electrically conductive transducer coil (16) configured to define an enclosure and being electrically coupled to the transducer to enable the transducer to be inductively operated by a remote device. The enclosure defined by the transducer coil has an internal width dimension that is wider than a corresponding width dimension of the transducer.