Strain sensor systems

• US 10,704,970 B1
• Filed: 03/06/2019
• Issued: 07/07/2020
• Est. Priority Date: 03/06/2019
• Status: Active Grant

• Current Assignee: GE Global Sourcing LLC (Westinghouse Air Brake Technologies Corporation)
• Original Assignee: GE Global Sourcing LLC (Westinghouse Air Brake Technologies Corporation)
• Inventors: Brown, Bradley, Ni, Tianshao, Sawatzky, Johann, Burchill, Richard, Procca, Michael, Lommen, Edward, Sholikowski, Cory
• Primary Examiner(s): Shah, Tanmay K
• Application Number:
  US16/294,592
• Time in Patent Office: 489 Days
• Field of Search: 340905
• CPC Class Codes: B61K 9/08 Measuring installations for surveying permanent way applications of measuring apparatus or devices for track building purposes E01B35/00; measuring techniques G01
• CPC Class Codes: B61L 23/042 Track changes detection
• CPC Class Codes: G01B 15/06 for measuring the deformation in a solid
• CPC Class Codes: G01L 1/106 Constructional details
• CPC Class Codes: G01L 1/142 using capacitors
• CPC Class Codes: G01L 1/25 using wave or particle radiation, e.g. X-rays , microwaves, neutrons G01L1/24 takes precedence
• CPC Class Codes: G01M 5/0058 of elongated objects, e.g. pipes, masts, towers or railways
• CPC Class Codes: G01M 5/0083 by measuring variation of impedance, e.g. resistance, capacitance, induction
• CPC Class Codes: G01S 13/753 using frequency selective elements, e.g. resonator
• CPC Class Codes: H01Q 1/2216 used in interrogator/reader equipment

Abstract

A strain sensor system emits coarse interrogation signals of different frequencies during a coarse scan while an RF resonant sensor and/or an RF interrogator moves relative to the other. The sensor emits responsive RF signals within a frequency range of a frequency of interest of the sensor. The controller identifies the frequency of interest based on receipt of the responsive signals. The interrogator emits fine interrogation signals of different frequencies during a fine scan subsequent to the coarse scan. The fine signals are emitted at frequencies within a frequency band on both sides of the frequency of interest. The sensor emits responsive RF signals and the controller identifies a center frequency of the RF resonant sensor based on receipt of the responsive signals.

Claims

1. A system for inspecting a rail of a railroad track, comprising:

a radio frequency (RF) resonant sensor;

an RF interrogator device; and

a controller configured to direct the RF interrogator device to emit coarse interrogation signals of different frequencies during a coarse scan of the rail of the railroad track, while at least one of the RF resonant sensor or the RF interrogator device, disposed on a rail vehicle, moves relative to another of the RF resonant sensor or the RF interrogator device,

wherein the RF resonant sensor is configured to emit a first responsive RF signal in response to receiving at least one of the coarse interrogation signals within a frequency range of a frequency of interest of the RF resonant sensor,

wherein the controller is configured to identify the frequency of interest of the RF resonant sensor based on receipt of the first responsive RF signal, the controller also configured to direct the RF interrogator device to emit fine interrogation signals of different frequencies during a fine scan subsequent to the coarse scan, the fine interrogation signals emitted at the different frequencies within a frequency band on both sides of the frequency of interest,

wherein the RF resonant sensor is configured to emit a second responsive RF signal in response to receiving at least one of the fine interrogation signals, and

wherein the controller is configured to identify a center frequency of the RF resonant sensor based on receipt of the second responsive RF signal.

2. The system of claim 1, wherein the controller is configured to direct the RF interrogator device to emit the coarse interrogation signals during the coarse scan at frequencies that are farther apart from each other than frequencies at which the fine interrogation signals are emitted during the fine scan.

3. The system of claim 1, wherein the controller is configured to adjust a gain of an antenna of the RF interrogator device as a distance between the RF interrogator device and the RF resonant sensor changes.

4. The system of claim 1, wherein the controller is configured to apply a frequency bias to one or more of the first RF responsive signal or the second RF responsive signal, and

wherein the controller is configured to identify one or more of the frequency of interest or the center frequency based on the one or more of the first RF responsive signal or the second RF responsive signal after the frequency bias is applied.

5. The system of claim 1, wherein the controller is configured to direct the RF interrogator device to change phases of one or more of the coarse interrogation signals or the fine interrogation signals based on changes in RF signal path length between the RF interrogator device and the RF sensor.

6. The system of claim 1, wherein the controller is configured to direct the RF interrogator device to emit the coarse interrogation signals and the fine interrogation signals toward the RF resonant sensor and the controller is configured to identify the frequency of interest is identified while the at least one of the RF resonant sensor or the RF interrogator device is moving relative to another of the RF resonant sensor or the RF interrogator device at a relative speed of at least 112 kilometers per hour.

7. The system of claim 1, wherein the RF interrogator device is configured to emit the coarse interrogation signals over a larger frequency band of at least 75 MHz, the RF interrogator is configured to emit the fine interrogation signals over a smaller frequency band of at least 12 MHz, and the controller is configured to identify the frequency of interest within a time window of 50 milliseconds or less.

8. The system of claim 1, wherein the RF resonant sensor includes a strain gauge having the center frequency of the first and second responsive RF signals that changes based on changes in strain in an object to which the strain gauge is coupled.

9. The system of claim 1, wherein the controller is configured to change phases of a baseband signal of one or more of the coarse interrogation signals or the fine interrogation signals, to receive multiple responsive signals having different phases from the RF resonant sensor, and to average the multiple responsive signals as one or more of the first responsive RF signal or the second responsive RF signal.

10. The system of claim 1, wherein the controller is configured to examine excitations of an antenna of the RF interrogator device during multiple temporal windows each having a data sub-window and a subsequent interference sub-window, the controller also configured to calculate a representative measurement of the excitations of the antenna during the interference sub-windows and to compare the representative measurements to a dynamically changing threshold, and

wherein the controller is configured to examine the excitations of the antenna during one or more of the data sub-windows as one or more of the first responsive RF signal or the second responsive RF signal based on comparing the representative measurements from the interference sub-windows to the dynamically changing threshold.

11. The system of claim 1, wherein the RF interrogator device includes:

an antenna configured to emit temperature interrogation RF signals toward one or more temperature sensors;

a dual directional coupler having a first directional coupler and a second directional coupler, each of the first directional coupler and the second directional coupler including an input port, an output port, a coupled port, and an isolated port, wherein the output port of the first directional coupler is connected with the output port of the second directional coupler and the antenna is connected with the input port of the second directional coupler;

a power amplifier configured to supply transmit power to the antenna for emitting the temperature interrogation signals, the power amplifier connected with the input port of the first directional coupler; and

a carrier suppression circuit configured to remove a carrier signal of the temperature interrogation signals from a responsive temperature RF signal received from the one or more temperature sensors, the carrier suppression circuit connected with the dual directional coupler at the coupled ports of the first and second directional couplers,

wherein the coupled ports of the dual directional coupler are isolated from each other by connecting the coupled port of the first directional coupler with the coupled port of the second directional coupler and by connecting each of the isolated ports of the first directional coupler and the second directional coupler with a ground reference.

12. The system of claim 1, wherein the resonant RF sensor includes an internal cavity between mounts configured to be coupled to an external body, the internal cavity having a resonating conductor disposed therein that resonates at different frequencies based on a separation distance between the mounts, and further comprising:

a restraint apparatus configured to restrict a size of the internal cavity such that the internal cavity of the RF sensor resonates at frequencies within a designated range.

13. The system of claim 1, wherein the controller is configured to determine one or more of (a) a geographic location of the RF resonant sensor, (b) an orientation of the RF resonant sensor on a body to which the RF resonant sensor is coupled, or (c) a time at which one or more of the first responsive RF signal or the second responsive RF signal is received, and further comprising:

an internal temperature sensor configured to measure a temperature of the RF resonant sensor; and

an external temperature sensor configured to measure a temperature of the body to which the RF resonant sensor is coupled,

wherein the controller is configured to modify one or more of the frequency of interest or the center frequency based on a combination of two or more of the temperature of the RF resonant sensor, the temperature of the body to which the RF resonant sensor is coupled, the geographic location of the RF resonant sensor, the orientation of the RF resonant sensor, or the time at which the first responsive RF signal or the second responsive RF signal is received.

14. A method comprising:

directing a radio frequency (RF) interrogator device to emit coarse interrogation signals of different frequencies during a coarse scan of an RF resonant sensor while at least one of the RF resonant sensor or the RF interrogator device moves relative to another of the RF resonant sensor or the RF interrogator device;

receiving a first responsive RF signal from the RF resonant sensor in response to the RF resonant sensor receiving at least one of the coarse interrogation signals within a frequency range of a frequency of interest of the RF resonant sensor;

identifying the frequency of interest of the RF resonant sensor based on receipt of the first responsive RF signal;

directing the RF interrogator device to emit fine interrogation signals of different frequencies during a fine scan after the coarse scan, the fine interrogation signals emitted at the different frequencies within a frequency band on both sides of the frequency of interest;

receiving a second responsive RF signal from the RF resonant sensor in response to receiving at least one of the fine interrogation signals; and

identifying a center frequency of the RF resonant sensor based on receipt of the second responsive RF signal.

15. The method of claim 14, further comprising:

directing the RF interrogator device to change phases of a baseband signal of one or more of the coarse interrogation signals or the fine interrogation signals;

receiving multiple responsive signals having different phases from the RF resonant sensor; and

averaging the multiple responsive signals to determine one or more of the first responsive RF signal or the second responsive RF signal.

16. The method of claim 14, further comprising:

examining excitations of an antenna of the RF interrogator device during multiple temporal windows each having a data sub-window and a subsequent interference sub-window;

calculating a representative measurement of the excitations of the antenna during the interference sub-windows;

comparing the representative measurements to a dynamically changing threshold; and

examining the excitations of the antenna during one or more of the data sub-windows as one or more of the first responsive RF signal or the second responsive RF signal based on comparing the representative measurements from the interference sub-windows to the dynamically changing threshold.

17. The method of claim 14, further comprising:

determining one or more of (a) a geographic location of the RF resonant sensor, (b) an orientation of the RF resonant sensor on a body to which the RF resonant sensor is coupled, or (c) a time at which one or more of the first responsive RF signal or the second responsive RF signal is received;

measuring a temperature of the RF resonant sensor;

measuring a temperature of the body to which the RF resonant sensor is coupled; and

modifying one or more of the frequency of interest or the center frequency based on a combination of two or more of the temperature of the RF resonant sensor, the temperature of the body to which the RF resonant sensor is coupled, the geographic location of the RF resonant sensor, the orientation of the RF resonant sensor, or the time at which the first responsive RF signal or the second responsive RF signal is received.

18. A method comprising:

obtaining an installation prescription associated with adhering a radio frequency (RF) resonant sensor to an external body, the installation prescription dictating one or more designated conditions in which to couple the RF resonant sensor to the external body using an adhesive;

determining one or more ambient conditions of the external body;

determining that the one or more ambient conditions differ from the one or more designated conditions of the installation prescription; and

modifying at least one of the ambient conditions based on determining that the one or more ambient conditions differ from the one or more designated conditions;

applying the adhesive to one or more of the RF resonant sensor or the external body;

coupling the RF resonant sensor with a first lateral side of the external body using the adhesive; and

rapidly curing the adhesive by heating an opposite second lateral side of the external body.

19. The method of claim 18, wherein the one or more designated conditions include one or more of a temperature range or a dew point in which to adhere the RF resonant sensor to the external body, and

wherein modifying the at least one ambient condition includes heating the external body to one or more of increase a temperature of the external body or increase the dew point.