Patent Document

CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority of U.S. Patent Application 61/639,375, filed Apr. 27, 2012 entitled AUTONOMOUS UPPER BIHECTO TEMPERATURE ACCELEROMETER SENSOR, which is hereby incorporated by reference in its entirety. 
    
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     This invention was made with government support under grant FA8650-09-C-5202 awarded by the United States Air Force. The United States government has certain rights in the invention. 
    
    
     REFERENCE TO A MICROFICHE APPENDIX 
     Not Applicable. 
     RESERVATION OF RIGHTS 
     A portion of the disclosure of this patent document contains material which is subject to intellectual property rights such as but not limited to copyright, trademark, and/or trade dress protection. The owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure as it appears in the Patent and Trademark Office patent files or records but otherwise reserves all rights whatsoever. 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to improvements in monitoring operation and performance of machinery. The present invention is specifically directed to remote electronic monitoring of bearing operation in high temperature and/or inaccessible environments. High temperature means operating ranges above normal electrical component temperatures such as environments above 225 degrees Celsius and below 300 degrees Celsius, hereafter referred to as the upper bihecto temperature range. In particular, the present invention relates to an unwired bearing sensor including a power generator, temperature and/or vibration sensors, and a wireless transmitter operable in the upper bihecto range. 
     2. Description of the Known Art 
     As will be appreciated by those skilled in the art, sensors are known in various forms. Patents disclosing information uncovered include: U.S. Pat. No. 8,050,875, issued to Karschnia on Nov. 1, 2011 entitled Steam trap monitoring; U.S. Pat. No. 7,901,546, issued to Miller, et al. on Mar. 8, 2011, entitled Monitoring methods, systems and apparatus for validating the operation of a current interrupter used in cathodic protection; U.S. Pat. No. 7,889,081, issued to McTigue on Feb. 15, 2011 entitled Thermal radio frequency identification system and method; U.S. Pat. No. 7,412,338, issued to Wynans, et al. on Aug. 12, 2008 entitled Radio frequency device within an energy sensor system; U.S. Pat. No. 7,251,570, issued to Hancock, et al. on Jul. 31, 2007, entitled Data integrity in a mesh network; and U.S. Pat. No. 7,224,080, issued to Smedstad on May 29, 2007 entitled Subsea power supply. Each of these patents is hereby expressly incorporated by reference in their entirety. 
     From these prior references it may be seen that these prior art patents are very limited in their teaching and utilization, and an improved upper bihecto temperature range, wireless, temperature and/or vibration sensor is needed to overcome these limitations. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to an improved autonomous sensor using high temperature components for operating in the upper bihecto range. In accordance with one exemplary embodiment of the present invention, an accelerometer is added for additional sensing. These and other objects and advantages of the present invention, along with features of novelty appurtenant thereto, will appear or become apparent by reviewing the following detailed description of the invention. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       In the following drawings, which form a part of the specification and which are to be construed in conjunction therewith, and in which like reference numerals have been employed throughout wherever possible to indicate like parts in the various views: 
         FIG. 1  is a perspective and exploded view of the autonomous sensor. 
         FIG. 2  is a system level diagram. 
         FIG. 3  is an electrical schematic of the sensor circuitry. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     As shown in  FIG. 1  of the drawings, one exemplary embodiment of the present invention is generally shown as an autonomous upper bihecto temperature accelerometer sensor system  100 . This autonomous wireless sensor system  100  is a culmination of technologies developed and integrated into a miniaturized, fully autonomous drop-in wireless transmitter system  100 . The invention includes novel approaches in the areas of both high temperature electrical circuit design as well as high temperature packaging.  FIG. 1  shows a picture of the autonomous wireless sensor system  100  as a low profile layout. The system level approach to this invention was the design of sensors, electrical circuitry, and power source that could be integrated together and function at the elevated temperatures experienced inside a jet turbine bearing sump. 
     Specifically, the components included a heat sink  101 , a piezoelectric accelerometer  102 , a sealing lid  103 , a thin-film thermal-electric generator, TEG  104 , a window ring  105 , wireless transmitter electrical circuitry  106 , substrate  107 , and baseplate  109 . 
     The packaging for this system is designed around the reliable high temperature integration of the system and circuit components. The circuit packaging is based off of previous APEI, Inc. high temperature packaging technology utilizing low temperature co-fired ceramic, LTCC, technology. The substrate contains multiple mechanical and electrical layers, with multiple cavity structures to securely house the electrical components in a high vibration environment. The components are mechanically attached inside the cavities utilizing high temperature epoxies, such as ABLEBOND JM7000 for conductive attaches, while EPOTEK 353 ND is used for non-conductive attachment. Most electrical connections are made utilizing gold and aluminum wire bonds, on both active and passive components. The substrates are attached to a separate substrate baseplate via a high temperature thick film brazing system, such as the DUPONT 5081/5082 thick film braze system. 
     The heat sink  101  is placed on top of the TEG  104 , and the heat sink is made from copper-tungsten for this prototype. 
     The piezoelectric accelerometer  102  is chosen to function at high temperatures and give a charge output proportional to the magnitude and frequency of bearing vibration. 
     Once the system is populated, the sealing lid  103  is seam sealed to the window ring  105 , providing a seal to keep out oil and moisture that is encountered in the bearing sump. 
     The thin-film thermal-electric generator TEG  104  delivers an electrical power output in response to a thermal gradient across it. 
     A window ring  105  is attached to the top of the substrate  107 . 
     The wireless transmitter electrical circuitry  106  serves to signal condition the accelerometer charge output, power condition the TEG output, and generate a wireless signal that contains vibration information from the accelerometer and internal temperature information of the electronics, and transmit that information to a remote location, such as an engine full authority digital engine control commonly referred to as a FADEC. 
     The substrate baseplate  107 , window ring,  105  and lid  103  are all comprised of a low expansion alloy such as Kovar, which has a good CTE match to the ceramic substrate. The substrate baseplate  107  is then attached to the main baseplate  109  via bolts, and electrical connections to the sensor and TEG are made with high temperature solders, brazes, or welding processes. 
     The baseplate  109  upon which the TEG  104 , the circuitry  106 , and the sensors  102  are mounted is made from a high thermal conductivity alloy to allow good heat transfer through the TEG assembly. In the prototype system, this alloy is a copper-tungsten Metal Matrix Composite (MMC), but may be comprised of any other metal of good thermal conductivity. The baseplate  109  is machined with bolt holes which allow for secure attachment of the individual system components. The accelerometer  102  is attached by stud mounting it into one of the machined bolt holes. 
     The system level blocks are depicted in  FIG. 2 . Beginning with the power subsystem  200 , the energy harvesting component  202  is a Thermal Electric Generator or alternatively some other energy harvesting device, such as vibration or radio frequency energy harvester, the energy storage component  204  may be either a high temperature capacitor, a high temperature molten salt battery, or a high temperature thin film battery. The power conditioning electronics  206  may include rectifiers, boost or buck converters, voltage regulators, current regulators, and filtering. The sensor  208  may be any type of high temperature accelerometer, thermocouple, resistive temperature detector, strain gauge, flow rate sensor, or pressure sensor. The signal conditioning block  210  may include any high temperature capable circuitry that can convert a sensor output into a signal capable of modulating a wireless carrier signal. The voltage controlled oscillator VCO  212  and Buffer/Power Amplifier components  214  may include any high temperature circuitry capable of producing and modulating a wireless carrier signal. 
       FIG. 3  shows the constructed embodiment of the circuitry  300  included in this invention which is comprised of components capable of high temperature operation, including transistors, diodes, resistors, capacitors, inductors, operational amplifiers, voltage regulators, timers, and varactors. In the prototype version of the system, the components included High Temperature Silicon on Insulator, HTSOI, integrated circuits, ICs, including a voltage regulator  302 , an operational amplifier  304 , and a 555 timer  306 . Also included were thick film passives including ceramic resistors and capacitors. The transistors and diodes included silicon carbide, SiC, JFETs, PIN, and SBDs. 
     The circuitry used in the prototype can be seen in  FIG. 3 . In the prototype version of this invention, the electrical output  310  of the TEG  104  was converted from a low voltage output of 0.5 to 2 V into a 6 to 8 V power signal via a boost converter  312 . The boost converter  312  utilizes a SiC JFET boost transistor  314  and a boost transformer  316  to function. The boost transistor  314  and boost transformer  316  are configured to self-oscillate at a very low voltage meaning less than &gt;0.5 V providing the boost converter&#39;s own switching signal. The boosted power signal  317  is then delivered through a filter network  320  and a high temperature silicon on insulator voltage regulator  302  to deliver a regulated 5 V output to the signal conditioning  340  and radio frequency circuits  350 . 
     In the prototype version of this invention, the accelerometer&#39;s charge output  332  is converted into a voltage output by using a high temperature silicon on insulator operational amplifier  304  and associated passives  334  in a charge amplifier configuration. This voltage is used as part of the modulating signal for the wireless carrier. 
     A 555 timer integrated circuit  306  is also configured as an astable multivibrator, with a temperature dependent resistor  342 . In this way, the frequency of the timer output is made to vary with temperature. This information is also modulated onto the carrier by the radio frequency circuits  350 . A silicon carbide JFET carrier transistor  352  is used to generate the RF carrier signal  354  by utilizing a Colpitts oscillator. One of the capacitors in the tank of the oscillator is constructed from a gallium nitride light emitting diode  356 , as its capacitance can be made to vary with the voltage of the modulating signal. In this manner, the carrier signal  354  becomes frequency modulated. The frequency modulated carrier signal  354  is then broadcast to a remote receiver through a high temperature antenna  358 . 
     The present invention discloses the development of extreme temperature, meaning up to 300° C., non-intrusive wireless sensor-transmitter suites using High-temperature Silicon on Insulator (HTSOI) electronics, and Silicon Carbide (SiC) electronics and the like, in conjunction with an innovative high-temperature packaging approach. This invention focuses on expanding new high-temperature wireless technology into a complete self-contained, self-powered wireless sensor-transmitter suite. The present invention has resulted in miniaturized and integrated technologies. This component will allow for a robust, reliable data transmitter that can operate in the bearing sump to deliver critical measurements such as temperature and vibration to the flight controller in real-time. 
     One application of this technology is integration into test engines for design validation. This allows engineers to receive data from test engines without the need to route wires, and the data is more accurate because the sensors can be located closer to the bearings and the signal integrity is not compromised due to noise picked up in the wiring. The system can be integrated into engines used in the field. This provides bearing health data that is superior to the current technology which detects metal particles in the oil stream. The early failure warning could save the lives of passengers and pilot, and it will prevent engine damage saving money on maintenance and lost equipment. In addition to the jet turbine market, there are several other markets that will benefit by the development of this technology. Electricity generation turbines can use this technology for compressor health monitoring. The technology can be modified to allow the industrial food processing industry to monitor the temperature of products while in a commercial oven. Additional sensors can be interfaced with the wireless transmitter to allow chemical processing industry to monitor their products while in production. 
     Reference numerals used throughout the detailed description and the drawings correspond to the following elements:
         autonomous wireless sensor system  100     heat sink  101     piezoelectric accelerometer  102     sealing lid  103     thin-film thermal-electric generator  104     window ring  105     wireless transmitter electrical circuitry  106     substrate  107     main baseplate  109     high temperature power subsystem  200     energy harvesting component  202     energy storage component  204     power conditioning electronics  206     high temperature sensor  208     signal conditioning block  210     voltage controlled oscillator  212     buffer power amplifier  214     high temperature sensor circuitry  300     voltage regulator  302     operational amplifier  304     timer  306     TEG electrical output  310     boost converter  312     boost transistor  314     boost transformer  316     boosted power signal  317     filter network  320     accelerometer&#39;s charge output  332     passive components  334     signal conditioning circuit  340     temperature dependent resistor  342     radio frequency circuits  350     carrier transistor  352     carrier signal  354     gallium nitride light emitting diode  356     high temperature antenna  358         

     From the foregoing, it will be seen that this invention well adapted to obtain all the ends and objects herein set forth, together with other advantages which are inherent to the structure. It will also be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations. This is contemplated by and is within the scope of the claims. Many possible embodiments may be made of the invention without departing from the scope thereof. Therefore, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense. 
     When interpreting the claims of this application, method claims may be recognized by the explicit use of the word ‘method’ in the preamble of the claims and the use of the ‘ing’ tense of the active word. Method claims should not be interpreted to have particular steps in a particular order unless the claim element specifically refers to a previous element, a previous action, or the result of a previous action. Apparatus claims may be recognized by the use of the word ‘apparatus’ in the preamble of the claim and should not be interpreted to have ‘means plus function language’ unless the word ‘means’ is specifically used in the claim element. The words ‘defining,’ ‘having,’ or ‘including’ should be interpreted as open ended claim language that allows additional elements or structures. Finally, where the claims recite “a” or “a first” element of the equivalent thereof, such claims should be understood to include incorporation of one or more such elements, neither requiring nor excluding two or more such elements.

Technology Category: 3