Wireless Sensor for Rotary Machinery Strain Monitoring

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Solution Overview

Problem

Existing wired sensors for measuring strain and temperature in rotary machinery are complex, expensive, and unreliable due to temperature limitations, making them impractical for continuous field monitoring.

Innovation Solution

A wireless sensor system comprising a resistive element and a modulating element on a rotating component, wirelessly coupled to a transmitting and receiving element, which modulates the wireless coupling to indicate strain or temperature changes, allowing for accurate measurements over a wide temperature range without active electronics or p/n junctions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If wired sensors are used to measure strain and temperature in rotary machinery, then measurements can be taken during testing, but the system becomes complex, expensive, and unreliable due to temperature limitations

Engineering Contradiction:

Improvestrain and temperature measurement accuracyVSAvoidwiring complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces the mechanical wired sensor system with a wireless sensing system that uses electromagnetic fields for signal transmission. The wireless sensor comprises a resonant circuit with a resonant frequency that changes in response to strain and temperature, allowing measurements without physical wiring connections to the rotating component.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a modulating element as an intermediary between the resistive element and the wireless transmission system. This modulating element couples the resistance changes from the sensing element to the wireless transmission without requiring direct wired connections, thereby reducing complexity while maintaining measurement capability.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If wired sensors are used, then measurements can be obtained, but reliability decreases at high temperatures due to electronic characteristics of the wiring

Engineering Contradiction:

Improvesensor reliabilityVSAvoidoperating temperature range

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent eliminates the wired electronic system that is temperature-sensitive by using a wireless resonant sensing approach. The resonant circuit and modulating element are designed to operate at high temperatures without the electronic limitations of wired sensors, enabling reliable operation up to 1200° F and above.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the operating parameters of the sensing system by using passive resonant elements and magnetic coupling that can withstand high temperatures. The resonant frequency and impedance of the wireless sensor are designed to remain stable across extreme temperature ranges, unlike conventional wired electronic sensors.

Inventive Principle:

Principle #35Parameter changes

3Duration of action of moving object

If wired sensors are used, then measurements can be taken during testing, but continuous monitoring during field operation becomes impractical

Engineering Contradiction:

Improvemonitoring durationVSAvoidfield operation practicality

Core Design Contradiction:

Duration of action of moving objectVSEase of operation

Solution Approach 1:

The patent replaces the impractical wired system with a wireless sensing system that can be easily installed on rotating components. The wireless sensor with its modulating element can transmit strain and temperature data continuously during field operation without the constraints of wiring, enabling long-term monitoring throughout the machinery's lifespan.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 and reliable strain and temperature monitoring in rotary machinery over its lifespan, even at high temperatures up to 1200° F, facilitating continuous health assessment and maintenance scheduling without the complexities and costs of wired systems.

Implementation Method 1

The modulating element modulates the wireless coupling, between the at least one of a transmitting element and a receiving element, in response to a change in resistance of the resistive element

Methodology Applied

Scientific EffectWireless coupling modulation: Electromagnetic Induction

Implementation Method 2

a resistive element; a modulating element located on a rotating component

Methodology Applied

Scientific EffectResistive sensing: Piezoresistive Effect

Data Source

PatentUS9086266B2Wireless sensors, detection methods, and systems

Publication Date: 2015.07.21 GENERAL ELECTRIC CO

AI summary

A wireless sensor including a resistive element, a modulating element located on a rotating component and at least one of a transmitting element and a receiving element, wirelessly coupled to the modulating element. The modulating element is configured to modulate the wireless coupling, between the at least one of a transmitting element and a receiving element, in response to a change in resistance in the resistive element. The modulation of the wireless coupling is indicative of a measurand on the rotating component. A method of detecting a measurand in a rotating component of a rotary machine includes wirelessly coupling at least one of a transmitting element and a receiving element to a modulating element; modulating the wireless coupling with the modulating element located on the rotating component; and calculating the measurand in the rotating component based on the modulation of the wireless coupling.