Wireless Sensor Construct for Conductive Surfaces
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Solution Overview
Problem
Traditional fuel quantity measurement methods in aerospace vehicles using electronic-capacitive probes require electrical penetrations through fuel tanks, which are prone to interference and fail when used with conductive materials like carbon fiber reinforced plastics (CFRPs), as they shield and absorb electromagnetic energy.
Innovation Solution
A multi-layer wireless sensor construct with an open-circuit, electrically unconnected spiral conductor and a mu metal layer that resonates in a time-varying magnetic field, allowing for non-invasive liquid detection without electrical connections, using an electromagnetic window to penetrate conductive materials and an impedance matching system for effective signal transmission and detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional electronic-capacitive probes are used for fuel quantity measurement, then measurement capability is achieved, but electrical penetrations through fuel tanks are required which are prone to interference and potential failure
Solution Approach 1:
The patent replaces traditional electronic-capacitive probes that require electrical penetrations with a wireless electromagnetic sensing system. The sensor uses electromagnetic fields to detect liquid quantity through the tank wall without physical electrical connections, eliminating the reliability issues associated with electrical penetrations and wiring while maintaining measurement capability.
2Reliability
If wireless electromagnetic sensors are used for non-invasive sensing, then no electrical penetrations are needed, but conductive materials like CFRPs shield and absorb the electromagnetic energy preventing sensor function
Solution Approach 1:
The patent modifies the electromagnetic sensor parameters by operating at resonant frequencies and adjusting the electromagnetic field characteristics to penetrate conductive CFRP materials. By changing the frequency and field parameters, the sensor overcomes the shielding effect of conductive materials while maintaining wireless operation without electrical penetrations.
Solution Approach 2:
The patent employs composite sensor construction combining conductive and non-conductive materials in specific configurations. The sensor uses conductive elements for electromagnetic resonance while incorporating non-conductive materials to manage interaction with CFRP tank walls, enabling effective penetration through conductive materials.
3Measurement precision
If probes are immersed in fuel for measurement, then direct contact sensing is achieved, but wire routing within fuel tank creates potential failure points and interference risks
Solution Approach 1:
The patent replaces the mechanical wire-based sensing system with a wireless electromagnetic field-based system. Instead of routing physical wires through the fuel tank to connect probes, the system uses electromagnetic fields for both sensing and data transmission, eliminating wire routing complexity and associated failure points while maintaining direct sensing capability through the tank wall.
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 accurate, non-invasive liquid quantity measurement in electrically conductive containers, such as those made of CFRPs, by effectively penetrating and sensing through the conductive materials, reducing interference and maintaining measurement accuracy across various attitudes and conditions.
Implementation Method 1
A layer of mu metal is provided on the first dielectric layer wherein the first dielectric layer separates the layer of mu metal from the first surface of the electrically-conductive material
Implementation Method 2
In the presence of a time-varying magnetic field, the electrical conductor so-shaped resonates to generate a harmonic magnetic field response having a frequency, amplitude and bandwidth
Data Source
AI summary
A multi-layer wireless sensor construct is provided. The construct includes a first dielectric layer adapted to be attached to a portion of a first surface of an electrically-conductive material. A layer of mu metal is provided on the first dielectric layer. A second dielectric layer is provided on the layer of mu metal. An electrical conductor is provided on the second dielectric layer wherein the second dielectric layer separates the electrical conductor from the layer of mu metal. The electrical conductor has first and second ends and is shaped to form an unconnected open-circuit that, in the presence of a time-varying magnetic field, resonates to generate a harmonic magnetic field response having a frequency, amplitude and bandwidth.