Patent Description:
When a ferromagnetic material (e.g., iron, nickel, cobalt etc.) is subjected to an external magnetic field, the magnetic domains within the material align, creating internal stress that causes the shape or the dimension of the materials to change. This phenomenon is referred to as magnetostriction. Conversely, when a magnetostrictive material is subjected to a stress, it's magnetic properties will change. This is known as the Villari effect.

Another manifestation of magnetostriction is the Wiedemann effect. When a wire is subjected to a magnetic field orientation parallel to its length, and a current is passed through the wire, then the wire experiences torsion strain at the location where the magnetic field occurs. In magnetostriction sensors, the wire may be referred to as a waveguide.

<FIG> is simplified diagram of a magnetostriction sensor <NUM> as known in the art. Sensor <NUM> includes a sensor element head <NUM>, a waveguide <NUM>, and a position magnet <NUM>. Waveguide <NUM> is protected by a sensing element protective tube <NUM>. A magnetic field <NUM> is provided by position magnet <NUM>. Position magnet <NUM> is attached to a moving portion of sensor <NUM> that is measured. Short pulses (e.g., <NUM>-<NUM> microseconds) of current are applied to waveguide <NUM>, which may be referred to as interrogation pulses <NUM>, which generate a moving magnetic field <NUM> that travels along waveguide <NUM>. Due to the Wiedemann effect, torsion strain <NUM> (twist) is induced in waveguide <NUM> due to the interaction of magnetic field <NUM> cause by interrogation pulse <NUM> and magnetic field <NUM> caused by position magnet <NUM>. Because the current is applied as a pulse, the twist travels along the wire at a known rate. The twist, or mechanical pulse, is detected by sensor head element <NUM>, which may rely on the Villari effect to create a voltage pulse indicating receipt of the mechanical strain wave or in some cases, may rely on a piezo sensor attached to waveguide <NUM> to create the voltage pulse indicating receipt of the mechanical strain wave.

The time between the interrogation pulse and the detection of the mechanical pulse indicates the location of position magnet <NUM> along waveguide <NUM>, and therefore, the position of the moving part being measured by sensor <NUM>. The moving part being measured by sensor <NUM> may include a float position in a tank, an orientation of a valve, etc..

Magnetostrictive sensors provide absolute position information and, unlike incremental encoders, do not need to be re-homed when there is a loss of power. They can also use multiple position magnets with one waveguide, making them well-suited for applications that require position information for multiple components along the same axis, such as level sensors that measure the position of fluids that have different densities in the same tank. Document <CIT> discloses a variable rejection level system for a magnetostrictive transducer which improves the detectability of magnetostrictive pulses along a waveguide in the presence of background noise in the waveguide.

Problems can arise, however, when magnetic field <NUM> generated by position magnet <NUM> degrades over time, which reduces the twist in waveguide <NUM> generated in response to interrogation pulse <NUM>. Another problem can arise when the connection between waveguide <NUM> and sensor element head <NUM> (e.g., glue) degrades over time. Both these degrading effects reduce the signal returned to sensor element head <NUM>, which ultimately renders sensor <NUM> unable to accurately detect the position of position magnet <NUM>. The result is that sensor <NUM> may fail unexpectedly, which is undesirable. Thus, it is desirable to mitigate the risks associated with unexpected failures that may occur for magnetostrictive sensors and to dynamically compensate for changes in sensor <NUM> that may occur over time.

In one aspect, a system for dynamically adjusting an operation of a magnetostrictive position sensor according to claim <NUM> is provided.

In another aspect, a method for dynamically adjusting an operation of a magnetostrictive position sensor according to claim <NUM> is provided.

In yet another aspect, a non-transitory computer readable medium including programmed instructions according to claim <NUM> is provided.

As used herein, the terms "processor" and "computer," and related terms, e.g., "processing device," "computing device," and "controller" are not limited to just those integrated circuits referred to in the art as a computer, but broadly refers to a microcontroller, a microcomputer, an analog computer, a programmable logic controller (PLC), an application specific integrated circuit (ASIC), and other programmable circuits, and these terms are used interchangeably herein. In the embodiments described herein, "memory" may include, but is not limited to, a computer-readable medium, such as a random-access memory (RAM), a computer-readable non-volatile medium, such as a flash memory. Alternatively, a floppy disk, a compact disc - read only memory (CD-ROM), a magneto-optical disk (MOD), and/or a digital versatile disc (DVD) may also be used. Also, in the embodiments described herein, additional input channels may be, but are not limited to, computer peripherals associated with an operator interface such as a touchscreen, a mouse, and a keyboard. Alternatively, other computer peripherals may also be used that may include, for example, but not be limited to, a scanner. Furthermore, in the example embodiment, additional output channels may include, but not be limited to, an operator interface monitor or heads-up display. Some embodiments involve the use of one or more electronic or computing devices. Such devices typically include a processor, processing device, or controller, such as a general purpose central processing unit (CPU), a graphics processing unit (GPU), a microcontroller, a reduced instruction set computer (RISC) processor, an ASIC, a programmable logic controller (PLC), a field programmable gate array (FPGA), a digital signal processing (DSP) device, and/or any other circuit or processing device capable of executing the functions described herein. The methods described herein may be encoded as executable instructions embodied in a computer readable medium, including, without limitation, a storage device and/or a memory device. Such instructions, when executed by a processing device, cause the processing device to perform at least a portion of the methods described herein. The above examples are not intended to limit in any way the definition and/or meaning of the term processor and processing device.

<FIG> is a block diagram of a system <NUM> for dynamically adjusting an operation of a magnetostrictive position sensor <NUM> in an example embodiment. In this embodiment, position sensor <NUM> includes a position magnet <NUM> that translates along a length <NUM> of position sensor <NUM>. System <NUM> in this embodiment includes a controller <NUM>, which is communicatively coupled to position sensor <NUM>. Controller <NUM> includes any component, system, or device that interrogates position sensor <NUM> to determine the position of position magnet <NUM> along length <NUM> of position sensor <NUM> and performs analysis in order to predict possible failures in position sensor <NUM> and/or to dynamically adjust the operation of position sensor <NUM>.

In this embodiment, controller <NUM> includes a current pulse circuit <NUM>, which includes any component, system, or device that generates and/or applies interrogation pulses <NUM> to position sensor <NUM> in order to determine the location of position magnet <NUM> along length <NUM> of position sensor <NUM>. Controller <NUM> further includes a signal conditioning circuit <NUM> which includes any component, system, or device that receives electrical signals <NUM> from position sensor <NUM> based on interrogation pulses <NUM>. Signal conditioning circuit <NUM> may include, for example, circuits that amplify electrical signals <NUM> received from position sensor <NUM> (e.g., variable gain circuits), circuits that filter electrical signals <NUM> received from position sensor <NUM>, etc..

Interrogation pulses <NUM> travel along a waveguide (e.g., a magnetostrictive wire, not shown) within position sensor <NUM>, and the magnetic field generated within the waveguide interacts with position magnet <NUM>, generating a torsional wave within the waveguide that is converted by position sensor <NUM> into electrical signals <NUM>. A time delay between interrogation pulses <NUM> and response pulses within electrical signals <NUM> correlates with the position of position magnet <NUM> along length <NUM> of position sensor <NUM>. Position sensor <NUM> may include float sensors, which measure levels of a fluid and/or translation sensors which provide information about a position or orientation of another device, such as a valve.

Controller <NUM> in this embodiment further includes a processor <NUM>. Processor <NUM> includes any component, system, or device which performs one or more functions described herein for controller <NUM>. Controller <NUM> in this embodiment further includes a memory <NUM>. Memory <NUM> includes any component, system, or device which stores data. In this embodiment, memory <NUM> stores calibration data <NUM> for position sensor <NUM>, which will be described below. In this embodiment, controller <NUM> further includes a display device <NUM>. Display device <NUM> includes any component, system, or device that presents information to a user.

<FIG> is a flow chart of a method <NUM> for dynamically adjusting an operation of a magnetostrictive position sensor in an example embodiment. Method <NUM> will be discussed with respect to system <NUM> of <FIG>, although method <NUM> may be performed by other systems, not shown. The steps of method <NUM> are not all inclusive, and method <NUM> may include other steps that are not shown. Further, the steps of method <NUM> may be performed in an alternative order.

Prior to placing position sensor <NUM> in service, calibration data <NUM> may be generated for position sensor <NUM> (e.g., at the factory), and stored in memory <NUM> of controller <NUM> (see <FIG>, at <NUM>). Calibration data <NUM> may include, for example various types of information about position sensor <NUM>. Such information may include, for example, information regarding electrical signals <NUM> received from position sensor <NUM> while position sensor <NUM> is a test environment. Such information may include how electrical signals <NUM> change as position magnet <NUM> moves along length <NUM> of position sensor <NUM>. For instance, if length <NUM> of position sensor <NUM> is long (e.g., <NUM>-<NUM> feet), then the twist induced in the waveguide of position sensor <NUM> travels a longer distance as compared to a short sensor (e.g., <NUM>-<NUM> feet), which reduces the amplitude of response pulses present in electrical signals <NUM> generated by position sensor <NUM>. The result is generally a decay in the amplitude of the response pulses present in electrical signals <NUM> as position magnet <NUM> moves to a distal end of position sensor <NUM>. In some embodiments, calibration data <NUM> may further include initial timestamp information (e.g., a date and time) generated when position sensor <NUM> is initially calibrated. The initial timestamp information may be used determine a rate of change of various criteria used to evaluate the performance of position sensor <NUM> over time, which will be described in more detail below.

depicts one type of calibration that may be performed on position sensor <NUM> in order to generate calibration data <NUM> for controller <NUM>. In particular, a first amplitude <NUM> of a first response pulse <NUM> in electrical signals <NUM> may be measured when position magnet <NUM> is a first distance d1 from a sensor head <NUM> of position sensor <NUM>, and a second amplitude <NUM> of a second response pulse <NUM> in electrical signals <NUM> may be measured when position magnet <NUM> is a second distance d2 from sensor head <NUM>. These measurements may be used to calculate the rate of change <NUM> or amplitude decay slope of response pulses <NUM>, <NUM> generated by position sensor <NUM>. Generally, sensor head <NUM> functions to convert strain pulses generated in the waveguide of position sensor <NUM> (not shown) into electrical signals <NUM>, and it is evident that amplitudes <NUM>, <NUM> of response pulses <NUM>, <NUM>, respectively, decrease as position magnet <NUM> moves along length <NUM> of position sensor <NUM> away from sensor head <NUM>, which is more pronounced as length <NUM> increases for position sensor <NUM>. Although only two calibration points are illustrated in <FIG>, calibration data <NUM> may include any number of calibration points.

Another type of calibration data <NUM> that may be calculated for position sensor <NUM> prior to placing position sensor <NUM> into service is the signal-to-noise ratio (SNR) of electrical signals <NUM> generated by position sensor <NUM>, which will be discussed in more detail below.

With calibration data <NUM> captured for position sensor <NUM> and stored in memory <NUM> of controller <NUM>, position sensor <NUM> is placed in service. For example, position sensor <NUM> may be used to determine a level in a tank (e.g., position magnet <NUM> is attached to a float that moves along length <NUM> of position sensor <NUM> depending on the level of the fluid in the tank). During normal operation of position sensor <NUM>, controller <NUM> interacts with position sensor <NUM> to calculate the location of position magnet <NUM> in order to display the level in the tank. Controller <NUM> also performs analysis on position sensor <NUM> during normal operation to determine or predict possible failures for position sensor <NUM>, perform automatic adjustments in order to maintain the performance of position sensor <NUM>, etc..

In order to perform these types of processes, controller <NUM> begins by applying interrogation pulse <NUM> to position sensor <NUM> (see <FIG>, at <NUM>). For example, processor <NUM> directs current pulse circuit <NUM> to generate and/or apply interrogation pulse <NUM> to the waveguide (not shown) of position sensor <NUM>. Controller <NUM> receives electrical signal <NUM> from position sensor <NUM> in response to interrogation pulse <NUM> (see <FIG>, at <NUM>). For example, interrogation pulse <NUM> generates a magnetic field in the waveguide of position sensor <NUM>, which interacts with position magnet <NUM> and generates a torsional wave in the waveguide. The torsional wave travels along the waveguide and is converted into electrical signal <NUM> (which includes a response pulse), and is received by signal conditioning circuit <NUM> of controller <NUM>. Signal conditioning circuit <NUM> may perform various signal processing steps to electrical signal <NUM>, including filtering processes, gain adjustment processes, etc..

Controller <NUM> measures an amplitude of the response pulse (see <FIG>, at <NUM>). In one example, processor <NUM> samples electrical signal <NUM> using an integrated analog-to-digital converter (ADC) to measure the amplitude of the response pulses. In another example, peak detection circuits or a separate ADC in signal conditioning circuit <NUM> is used to measure the amplitude of the response pulse.

Controller <NUM> identifies calibration data <NUM> that correlates the initial recorded values of response pulses at different locations along length <NUM> of position sensor <NUM> (see <FIG>, at <NUM>). For example, processor <NUM> recovers calibration data <NUM> stored in memory <NUM>, which was generated prior to placing position sensor <NUM> into service.

Controller <NUM> then calculates a location of position magnet <NUM> along length <NUM> of position sensor <NUM> based on a time delay between interrogation pulse <NUM> and the response pulse in electrical signal <NUM> (see <FIG>, at <NUM>). For example, processor <NUM> or some other dedicated hardware (e.g., a programmable logic device) may perform a high-accurate measurement of the time delay between interrogation pulse <NUM> and the response pulse in electrical signal <NUM>, and use the time delay as an entry in a lookup table or transfer function associated with position sensor <NUM>. In some embodiments, the lookup table or transfer function may be stored in calibration data <NUM>, generated during the factory calibration for position sensor <NUM>. For instance, the time delays associated with response pulses <NUM>, <NUM> (see <FIG>) may be used to derive a function of time delay over length <NUM> of position sensor <NUM>.

Using the location of position magnet <NUM> and calibration data <NUM>, controller <NUM> identifies an initial amplitude of the response pulse in electrical signal <NUM>. For example, if position magnet <NUM> is located at d1 (depicted in <FIG>), then the initial amplitude of response pulse <NUM> corresponds to amplitude <NUM>, stored in calibration data <NUM>. If position magnet <NUM> is located at d2 (depicted in <FIG>), then the initial amplitude of response pulse <NUM> corresponds to amplitude <NUM>, also stored in calibration data <NUM>. If position magnet <NUM> is located between d1 and d2, then the amplitude of the corresponding response pulse varies as a function of rate of change <NUM>, also stored in calibration data <NUM>.

Controller <NUM> calculates a difference between the initial amplitude of the response pulse and the measured amplitude of the response pulse. Differences may arise, for example, due to aging of position sensor <NUM>. For instance, the magnetic field generated by position magnet <NUM> may decrease over time, which reduces the twist induced in the waveguide of position sensor <NUM> in response to interrogation pulses <NUM>. In another example, the mechanical attachment of the waveguide of position sensor <NUM> to its sensor head <NUM> may degrade over time, which reduces the ability of position sensor <NUM> to detect the twist in the waveguide.

Controller <NUM> determines if the difference is greater than a threshold value (see <FIG>, at <NUM>), and generates an alert (e.g., using display device <NUM>, see <FIG>, at <NUM>) if the difference between the initial amplitudes of the response pulses and the measure amplitude of the response pulse is greater than the threshold value. For example, an alert may be generated if the measured amplitude of the response pulse while position sensor <NUM> is in service is about <NUM>% of the initial amplitude at calibration, about <NUM>%, about <NUM>%, about <NUM>%, between about <NUM>% and about <NUM>%, or some other suitable value. The alert may, for example, provide information to a maintenance worker about the type of error (e.g., degraded performance of position sensor <NUM>), thereby allowing the maintenance worker to schedule maintenance or a replacement activity for position sensor <NUM>. If the difference is not greater than the threshold value, then the controller <NUM> displays the level/position information based on the location of position magnet <NUM> along length <NUM> of position sensor <NUM> (see <FIG>, at <NUM>).

In some embodiments, controller <NUM> analyzes the rate of change of the difference over time in order to generate an alert and/or to provide a suggestion for scheduling maintenance and/or to indicate a pending failure of position sensor <NUM> (e.g., using display device <NUM>). For instance, controller <NUM> may provide a suggestion for scheduling maintenance if the rate of change is less than a threshold rate, while indicating a pending failure of position sensor <NUM> if the rate of change is greater than the threshold rate. However, controller <NUM> may utilize other criteria when generating alerts, and/or providing suggestions for scheduling maintenance, and/or for indicating a pending failure, such as utilizing differing thresholds for the rate of change, the acceleration of the rate of change over time, etc..

In some embodiments, controller <NUM> generates a timestamp upon first determining that the difference is greater than the threshold value (e.g., the first application of dynamic compensation for this criteria), and utilizes the initial timestamp stored in calibration data <NUM> in order to calculate a rate of change of the difference over time. In other embodiments, controller <NUM> generates and stores in memory <NUM>, timestamps when dynamic compensation is performed based on the difference being greater than the threshold value. In this embodiment, controller <NUM> utilizes successive timestamps and/or timestamps in a temporal sequence in order to calculate the rate of change of the difference over time.

In some embodiments, controller <NUM> amplifies electrical signal <NUM> received from position sensor <NUM> in response to determining that the difference is greater than the threshold value. For instance, processor <NUM> may vary an input amplifier gain stage at signal conditioning circuit <NUM>, which increases the amplitude of response pulses received from position sensor <NUM>. However, increasing the gain applied to electrical signals <NUM> amplifies both the response pulses and the noise included in electrical signals <NUM>, which can be mitigated in other ways, described below.

In some embodiments, controller <NUM> calculates a rate of change of amplitudes of the response pulses over length <NUM> of position sensor <NUM> (e.g., an amplitude decay slope), determines if the rate of change is greater than a target rate of change, and generates an alert in response to determining that the rate of change is greater than a target rate of change. For example, during operation of position sensor <NUM>, movement of position magnet <NUM> along length <NUM> of position sensor <NUM> allows amplitudes of response pulses generated by position sensor <NUM> to be recorded, which are used to generate a new decay rate or rate function for the amplitudes over length <NUM>. When the rate varies from the rate initially determined in calibration (e.g., amplitude <NUM> of response pulse <NUM> at d2 is greater than what is measured when position magnet <NUM> is at d2 while position sensor <NUM> is in service), then an alert may be generated indicating a problem with position sensor <NUM> (e.g., problems with sensor head <NUM>). Another type of problem that can arise is when position sensor <NUM> is flexible and is bent by accident while in service. In this case, the amplitude of the response pulses when position magnet <NUM> is located at about d1 may be similar to amplitude <NUM>, recorded in calibration, but the amplitude of response pulses when position magnet <NUM> is located at about d2 may be less than, or substantially less than, amplitude <NUM>, recorded in calibration. This particular case is detectable and reportable as an alert. For instance, controller <NUM> may utilize display device <NUM> to indicate to a user that position sensor <NUM> is bent, thereby allowing the user to correct the situation. In some embodiments, controller <NUM> may modify a comparison value used to identify the response pulse in electrical signal <NUM> when position sensor <NUM> is bent, thereby improving the performance of system <NUM>.

In some embodiments, controller <NUM> analyzes the rate of change of the amplitude decay slope over time in order to generate an alert and/or to provide a suggestion for scheduling maintenance and/or to indicate a pending failure of position sensor <NUM> (e.g., using display device <NUM>). For instance, controller <NUM> may provide a suggestion for scheduling maintenance if the rate of change of the amplitude decay slope is less than a threshold rate, while indicating a pending failure of position sensor <NUM> if the rate of change of the amplitude decay slope is greater than the threshold rate. However, controller <NUM> may utilize other criteria when generating alerts, and/or providing suggestions for scheduling maintenance, and/or for indicating a pending failure, such as utilizing differing thresholds for the rate of change of the amplitude decay slope, the acceleration of the rate of change over time of the amplitude decay slope, etc..

In some embodiments, controller <NUM> generates a timestamp upon first determining that the amplitude decay slope is greater than the target rate (e.g., the first application of dynamic compensation for this criteria), and utilizes the initial timestamp stored in calibration data <NUM> in order to calculate a rate of change of the amplitude decay slope over time. In other embodiments, controller <NUM> generates and stores in memory <NUM>, timestamps when dynamic compensation is performed based on the amplitude decay slope being greater than the target rate. In this embodiment, controller <NUM> utilizes successive timestamps and/or timestamps in a temporal sequence in order to calculate the rate of change of the amplitude decay slope over time.

<FIG> depicts electrical signal <NUM> and a response pulse <NUM> in an example embodiment. In this embodiment, response pulse <NUM> is depicted as having an amplitude <NUM>. A threshold <NUM> (i.e., a comparison value) is used by controller <NUM> when analyzing electrical signal <NUM> from position sensor <NUM> to detect or determine when response pulse <NUM> is valid and also for determining the time delay between interrogation pulses <NUM> and response pulse <NUM> for locating position magnet <NUM> along length <NUM> of position sensor <NUM>. For example, controller <NUM> may consider the end of the time delay to occur at point <NUM> in <FIG> when response pulse <NUM> is negative-crossing on threshold <NUM> and is zero-crossing at a zero-voltage level <NUM>.

In some embodiments, controller <NUM> dynamically adjusts threshold <NUM> in response to various parameters measured in electrical signal <NUM>. For instance, controller <NUM> may adjust threshold <NUM> in response to determining that position sensor <NUM> is bent.

In one embodiment, controller <NUM> measures a peak amplitude <NUM> of noise in electrical signal <NUM>, determines a difference <NUM> between peak amplitude <NUM> of the noise and amplitude <NUM> of response pulse <NUM>, and modifies threshold <NUM> when difference <NUM> is less than a threshold amount. For instance, it may be desirable that threshold <NUM> is about half of difference <NUM> is some embodiments. This type of dynamic modification while position sensor <NUM> is in operation enables controller <NUM> to respond to different noise environments that may be changing over time, which may modify the value of peak amplitude <NUM> of the noise in electrical signal <NUM>. <FIG> depicts one example of this process whereby a new threshold <NUM> is used in response to changes in peak amplitude <NUM> of noise <NUM> present in electrical signal <NUM>.

In some embodiments, controller <NUM> dynamically makes changes in how it operates based on changes in the SNR of electrical signals <NUM>. For instance, calibration data <NUM> may store initial SNR information captured during calibration for position sensor <NUM>, and processor <NUM> may dynamically calculate the SNR of electrical signals <NUM> during operation, determining the differences between the initial SNR for position sensor <NUM> and the measured SNR for position sensor <NUM>. Controller <NUM> may also generate alerts when the initial SNR and the measured SNR differ from each other by a target SNR. In some embodiments, controller <NUM> may take additional actions, such as adjusting the gain applied to electrical signal <NUM>, modifying threshold <NUM>, etc., in response to changes in the measured values of SNR for electrical signals <NUM> during operation of position sensor <NUM>.

In some embodiments, controller <NUM> analyzes the rate of change of the SNR over time in order to generate an alert and/or to provide a suggestion for scheduling maintenance and/or to indicate a pending failure of position sensor <NUM> (e.g., using display device <NUM>). For instance, controller <NUM> may provide a suggestion for scheduling maintenance if the rate of change is less than a threshold rate, while indicating a pending failure of position sensor <NUM> if the rate of change is greater than the threshold rate. However, controller <NUM> may utilize other criteria when generating alerts, and/or providing suggestions for scheduling maintenance, and/or for indicating a pending failure, such as utilizing differing thresholds for the rate of change, the acceleration of the rate of change over time, etc..

In some embodiments, controller <NUM> generates a timestamp upon first determining that the difference between the initial SNR and the measured SNR differ from each other by the target SNR (e.g., the initial application of dynamic compensation for this criteria), and utilizes the initial timestamp stored in calibration data <NUM> in order to calculate a rate of change of the SNR over time. In other embodiments, controller <NUM> generates and stores in memory <NUM>, timestamps when dynamic compensation is performed based on the SNR. In this embodiment, controller <NUM> utilizes successive timestamps and/or timestamps in a temporal sequence in order to calculate the rate of change of the SNR over time.

In yet another embodiment, controller <NUM> dynamically adjusts to different noise sources that may affect electrical signal <NUM> over time. In this embodiment, controller <NUM> measures peak amplitude <NUM> of noise in electrical signal <NUM> and calculates a sum of a magnitude of the noise in electrical signal <NUM>. Controller <NUM> then calculates a ratio of the peak amplitude <NUM> of the noise and the sum of the magnitude of the noise, determines if the ratio is greater than a threshold ratio, and modifies threshold <NUM> when the ratio is greater than the threshold ratio. In some embodiments, controller <NUM> may generate an alert indicating such and/or adjusting the gain applied to electrical signal <NUM>.

An example technical effect of the apparatus and method described herein includes one or more of: (a) adjusting the operation of magnetostrictive position sensors as components on magnetostrictive position sensors age; (b) dynamically altering the operation of magnetostrictive position sensors in the presence of noise; (c) providing real-time or near real-time status for magnetostrictive position sensors to operators; (d) detecting fault conditions in magnetostrictive position sensors including bent probes; and (e) dynamically adjusting the operation of magnetostrictive position sensors based on changes in noise sources.

Although specific features of various embodiments of the disclosure may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the disclosure, any feature of a drawing may be referenced in combination with any feature of any other drawing, unless departing from the scope of protection conferred by the appended claims.

Claim 1:
A system (<NUM>) for dynamically adjusting an operation of a magnetostrictive position sensor (<NUM>), the system (<NUM>) comprising:
a controller (<NUM>) configured to:
receive an electrical signal (<NUM>) from the magnetostrictive position sensor (<NUM>) that includes a response pulse (<NUM>);
identify factory calibration data (<NUM>) that correlates initial recorded values of amplitudes (<NUM>, <NUM>) of response pulses (<NUM>, <NUM>) received from the magnetostrictive position sensor (<NUM>) at different locations (d1, d2) of a position magnet (<NUM>) along a length (<NUM>) of the magnetostrictive position sensor (<NUM>);
identify an initial amplitude (<NUM>, <NUM>) of the response pulse (<NUM>) based on the factory calibration data (<NUM>);
calculate a difference between the initial amplitude (<NUM>, <NUM>) and an amplitude (<NUM>) of the response pulse (<NUM>);
determine if the difference is greater than a threshold value (<NUM>); and
generate an alert in response to determining that the difference is greater than the threshold value (<NUM>).