Embedded sensor system

• US 10,107,132 B2
• Filed: 05/05/2015
• Issued: 10/23/2018
• Est. Priority Date: 05/05/2015
• Status: Active Grant

• Current Assignee: Rtx Corporation
• Original Assignee: United Technologies Corporation (Rtx Corporation)
• Inventors: Wu, Xin, Soldner, Nicholas Charles, Tokgoz, Cagatay, Mantese, Joseph V., Zacchio, Joseph
• Primary Examiner(s): Shah, Manish S
• Assistant Examiner(s): Graves, Timothy
• Application Number:
  US14/704,715
• Publication Number:
  US 20160326904A1
• Time in Patent Office: 1,267 Days
• CPC Class Codes: F01D 17/02 Arrangement of sensing elements
• CPC Class Codes: F01D 17/20 Devices dealing with sensing elements or final actuators or transmitting means between them, e.g. power-assisted sensing elements alone F01D17/02; final actuators alone F01D17/10
• CPC Class Codes: F01D 21/003 Arrangements for testing or measuring for measuring vibrations G01H
• CPC Class Codes: F01D 5/28 Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
• CPC Class Codes: F05D 2300/507 Magnetic properties
• CPC Class Codes: G06K 19/07771 the record carrier comprising means for minimising adverse effects on the data communication capability of the record carrier, e.g. minimising Eddy currents induced in a proximate metal or otherwise electromagnetically interfering object
• CPC Class Codes: G06K 19/07777 the antenna being of the inductive type
• CPC Class Codes: H04Q 2209/40 using a wireless architecture
• CPC Class Codes: H04Q 9/00 Arrangements in telecontrol or telemetry systems for selectively calling a substation from a main station, in which substation desired apparatus is selected for applying a control signal thereto or for obtaining measured values therefrom

Abstract

A magnetic communication system for a gas turbine engine may include a sensor coupled to a microcontroller. A low frequency radio-frequency identification integrated chip may be coupled to the microcontroller. A first coupling circuit may be coupled to the low frequency radio-frequency identification integrated chip and may include a first coil winding wound within a first core. The first coil winding operatively associated with a low frequency magnetic flux.

Claims

1. A system for a gas turbine engine, comprising:

a rotary component comprising one or more of an airfoil, a blade, a nacelle and a vane for the gas turbine engine, the rotary component including;

a conductive metallic surface having a first portion forming an airfoil,

a sensor system embedded as a discrete system within the first portion of the conductive metallic surface, wherein communications therefrom penetrates through the conductive metallic surface,

the sensor system including a magnetic communication system comprising a microcontroller, a sensor coupled to the microcontroller, and a low frequency radio-frequency identification integrated-chip coupled to the microcontroller, and a first coupling circuit of a plurality of coupling circuits, the first coupling circuit coupled to the low frequency radio-frequency identification integrated-chip, and

a stationary component being external to and proximate the rotary component, the stationary component including a low frequency reader and a second coupling circuit of the plurality of coupling circuits, the second coupling circuit coupled to the low frequency reader;

each of the plurality of coupling circuits including a capacitor and an inductor, the inductor including a coil winding wound within a core, the coil winding operatively associated with a low frequency magnetic flux, the core comprising a p-core shape (pot core) that includes a base, an outer wall that is cylindrically shaped and extends from the base, the outer wall circumscribing an inner pillar that extends from the base of the core, the core being a ferromagnetic material and the outer wall being spaced apart from the inner pillar such that the coil winding winds around the inner pillar therebetween, and the outer wall including a first slot and a second slot, the a first portion of the coil winding exits the core through the first slot and a second portion of the coil winding exits the core through the second slot,

wherein

in the rotary component, the first portion of the coil winding connects to the low frequency radio-frequency identification integrated-chip, and the second portion of the coil winding connects to the low frequency radio-frequency identification integrated-chip through the capacitor,

in the stationary component, the first portion of the coil winding connects to the low frequency reader, and the second portion of the coil winding connects to the low frequency reader through the capacitor, and

each of the plurality of coupling circuits produces a magnetic flux from the respective core that is similarly concentrated and directed to generate a magnetic flux coupling between the plurality of coupling circuits and to transfer power and data between the external reader and the sensor system.

2. The component of claim 1, wherein the first coil winding is a copper winding.

3. The component of claim 1, wherein the sensor is one of a digital sensor and an analog sensor.

4. The component of claim 1, wherein the sensor is one of an acceleration sensor, a temperature sensor, and a strain sensor.

5. A gas turbine engine, the engine comprising:

a rotary component comprising one or more of an airfoil, a blade, a nacelle and a vane for the gas turbine engine, the rotary component including;

a conductive metallic surface having a first portion forming an airfoil,

a sensor system embedded as a discrete system within the first portion of the conductive metallic surface, wherein communications therefrom penetrates through the conductive metallic surface,

the sensor system including a magnetic communication system comprising a microcontroller, a sensor coupled to the microcontroller, and a low frequency radio-frequency identification integrated-chip coupled to the microcontroller, and a first coupling circuit of a plurality of coupling circuits, the first coupling circuit coupled to the low frequency radio-frequency identification integrated-chip, and

a stationary component being external to and proximate the rotary component, the stationary component including a low frequency reader and a second coupling circuit of the plurality of coupling circuits, the second coupling circuit coupled to the low frequency reader;

each of the plurality of coupling circuits including a capacitor and an inductor, the inductor including a coil winding wound within a core, the coil winding operatively associated with a low frequency magnetic flux, the core comprising a p-core shape (pot core) that includes a base, an outer wall that is cylindrically shaped and extends from the base, the outer wall circumscribing an inner pillar that extends from the base of the core, the core being a ferromagnetic material and the outer wall being spaced apart from the inner pillar such that the coil winding winds around the inner pillar therebetween, and the outer wall including a first slot and a second slot, the a first portion of the coil winding exits the core through the first slot and a second portion of the coil winding exits the core through the second slot,

wherein

in the rotary component, the first portion of the coil winding connects to the low frequency radio-frequency identification integrated-chip, and the second portion of the coil winding connects to the low frequency radio-frequency identification integrated-chip through the capacitor,

in the stationary component, the first portion of the coil winding connects to the low frequency reader, and the second portion of the coil winding connects to the low frequency reader through the capacitor, and

each of the plurality of coupling circuits produces a magnetic flux from the respective core that is similarly concentrated and directed to generate a magnetic flux coupling between the plurality of coupling circuits and to transfer power and data between the external reader and the sensor system.

6. The gas turbine engine of claim 5, wherein the first coil winding is a copper winding.

7. The gas turbine engine of claim 5, wherein the sensor is one of a digital sensor and an analog sensor.

8. The gas turbine engine of claim 5, wherein the sensor is one of an acceleration sensor, a temperature sensor, and a strain sensor.

9. A method of wirelessly communicating between a sensor system embedded in a rotary component of a gas turbine engine, and an external reader in a stationary component by reducing eddy currents produced therefrom,

wherein:

the rotary component comprises one or more of an airfoil, a blade, a nacelle and a vane for the gas turbine engine, the rotary component including;

a conductive metallic surface having a first portion forming an airfoil,

a sensor system embedded as a discrete system within the first portion of the conductive metallic surface, wherein communications therefrom penetrates through the conductive metallic surface,

the sensor system including a magnetic communication system comprising a microcontroller, a sensor coupled to the microcontroller, and a low frequency radio-frequency identification integrated-chip coupled to the microcontroller, and a first coupling circuit of a plurality of coupling circuits, the first coupling circuit coupled to the low frequency radio-frequency identification integrated-chip, and

the stationary component is external to and proximate the rotary component, the stationary component including a low frequency reader and a second coupling circuit of the plurality of coupling circuits, the second coupling circuit coupled to the low frequency reader;

each of the plurality of coupling circuits includes a capacitor and an inductor, the inductor including a coil winding wound within a core, the coil winding operatively associated with a low frequency magnetic flux, the core comprising a p-core shape (pot core) that includes a base, an outer wall that is cylindrically shaped and extends from the base, the outer wall circumscribing an inner pillar that extends from the base of the core, the core being a ferromagnetic material and the outer wall being spaced apart from the inner pillar such that the coil winding winds around the inner pillar therebetween, and the outer wall including a first slot and a second slot, the a first portion of the coil winding exits the core through the first slot and a second portion of the coil winding exits the core through the second slot,

wherein

in the rotary component, the first portion of the coil winding connects to the low frequency radio-frequency identification integrated-chip, and the second portion of the coil winding connects to the low frequency radio-frequency identification integrated-chip through the capacitor,

in the stationary component, the first portion of the coil winding connects to the low frequency reader, and the second portion of the coil winding connects to the low frequency reader through the capacitor, and

the method comprising;

each of the plurality of coupling circuits producing a magnetic flux from the respective core that is similarly concentrated and directed to generate a magnetic flux coupling between the plurality of coupling circuits and to transfer power and data between the external reader and the sensor system.

10. The method of claim 9, wherein the second core is manufactured from a ferromagnetic material.

11. The method of claim 9, wherein the sensor system includes one of an acceleration sensor, a temperature sensor, and a strain sensor.

12. The method of claim 9, wherein the sensor system includes one of a digital sensor and an analog sensor.