Optoelectronic Strain-Measurement System Demonstrated on Scaled-Down Flywheels.

Monitoring the strain in the rotating flywheel in a kinetic energy storage system is important for safe operation and for the investigation of long-term effects in composite materials like carbon-fiber-reinforced plastics. An optoelectronic strain-measurement system for contactless deformation and position monitoring of a flywheel was investigated. The system consists of multiple optical sensors measuring the local relative in-plane displacement of the flywheel rotor. A special reflective pattern, which is necessary to interact with the sensors, was applied to the surface of the rotor. Combining the measurements from multiple sensors makes it possible to distinguish between the deformation and in-plane displacement of the flywheel. The sensor system was evaluated using a low-speed steel rotor for single-sensor performance investigation as well as a scaled-down high-speed rotor made from PVC plastic. The PVC rotor exhibits more deformation due to centrifugal stresses than a steel or aluminum rotor of the same dimensions, which allows experimental measurements at a smaller flywheel scale as well as a lower rotation speed. Deformation measurements were compared to expected deformation from calculations. The influence of sensor distance was investigated. Deformation and position measurements as well as derived imbalance measurements were demonstrated.

Eddy Current Position Measurement in Harsh Environments: A Temperature Compensation and Calibration Approach.

Eddy current displacement sensors (ECDSs) are widely used for the noncontact position measurement of small displacements (lift-offs). Challenges arise with larger displacements as the sensitivity of the ECDSs decreases. This leads to a more pronounced impact of temperature variations on the inductance and, consequently, an increased position error. Design solutions often rely on multiple coils, suitable coil carrier materials, and compensation measures to address the challenges. This study presents a single-coil ECDS for large displacement ranges in environments with high temperatures and temperature variations. The analysis is based on a sensor model derived from an equivalent circuit model (ECM). We propose design measures for both the sensing coil and the target, focusing on material selection to handle the impact of temperature variations. A key part of improving performance under varying temperatures includes model-based temperature compensation for the inductance of the sensing coil. We introduce a method to calibrate the sensor for large displacements, using a modified coupling coefficient based on field simulation data. Our analysis shows that this single-coil ECDS design maintains a position error of less than 0.2% full-scale for a temperature variation of 100 K for the sensing coil and 110 K for the target.

Transmission Lines in Capacitance Measurement Systems: An Investigation of Receiver Structures.

Dielectric sensing based on capacitive measurement technology is a favourable measurement approach in many industries and fields of application. From an electrical point of view, a coupling capacitance must be measured in the presence of stray capacitances. Different receiver circuit structures have been proposed for the underlying displacement current measurement. Ideally, the sensor assembly is directly connected to the sensor circuitry to minimize the influence with respect to these parasitic capacitances. However, under harsh operating conditions, e.g., at high temperatures, the sensor and the receiver circuit must be separated in order to protect the electronics. Consequently, the receiver circuit and the sensor have to be connected by cables, e.g., coaxial cables. The measurement setup differs significantly from the ideal design with a direct connection. In this paper, we investigate the behaviour of three common measurement circuits for capacitive measurements in instrumentations with cables. We study the interaction between the sensor and the electronics and analyse the operating behaviour of the circuit, as well as the operating states of the amplifiers used. We also address cross-sensitivities in the sensor design due to stray capacitances. The analyses are carried out for different cable lengths and measuring frequencies, and conditions for the usability of the circuit are deduced. In addition to the operational behaviour, we also evaluate the circuits by means of a noise analyses. Based on this analysis, we show a direct comparison of the circuits. The analysis is based on simulation studies, as well as collaborative measurements on test circuits where all circuit parameters are provided. The test circuits are realized with dedicated state-of-the-art circuit elements and, together with the analysis approach and the results, thus provide a basis for future developments.

Excitation of Mechanical Resonances in the Stationary Ring of a Mechanical Seal by a Continuously Operated Electromagnetic Acoustic Transducer.

Acoustic/ultrasonic testing is now a common method in the field of nondestructive testing for detecting material defects or monitoring ongoing mechanical changes in a structure during operation. In many applications, piezoelectric transducers are used to generate mechanical waves inside the specimen. Their actual operating frequency is highly dependent on the dimensions of the transducer. Larger dimensions of the piezoelectric transducer allow for a lower operating frequency. However, these dimensions limit the use of piezoelectric transducers in certain applications where the size of the transducer is restricted due to limited installation space and when low-frequency excitation is required. One application that places these requirements on the transducer is the monitoring of mechanical seals. Here, the transducer must be mounted on the stationary ring of the seal. In this paper, a continuously operated electromagnetic acoustic transducer (EMAT) is presented as an alternative to piezoelectric transducers as a transmitter. The advantage of a EMAT is that it meets the requirements of limited sensor size (sensor area < 10 × 6 mm) and can excite mechanical waves with frequencies below 10 kHz. A structural analysis of the stationary ring shows that the first two mechanical resonances occur around 4 and 5.5 kHz. An experimental study meterologically demonstrates the ability of the EMAT to excite these first two mechanical resonances of the ring. A comparative simulation agrees well with the measurement.

A Model-Based Analysis of Capacitive Flow Metering for Pneumatic Conveying Systems: A Comparison between Calibration-Based and Tomographic Approaches.

Pneumatic conveying is a standard transportation technique for bulk materials in various industrial fields. Flow metering is crucial for the efficient and reliable operation of such systems and for process control. Capacitive measurement systems are often proposed for this application. In this method, electrodes are placed on the conveyor systems transport line and capacitive signals are sensed. The design of the sensor with regard to the arrangement and the number of electrodes as well as the evaluation of the capacitive sensor signals can be divided into two categories. Calibration-based flow meters use regression methods for signal processing, which are parametrized from calibration measurements on test rigs. Their performance is limited by the extend of the calibration measurements. Electrical capacitance tomography based flow meters use model-based signal processing techniques to obtain estimates about the spatial material distribution within the sensor. In contrast to their calibration-based counterparts, this approach requires more effort with respect to modeling and instrumentation, as typically a larger number of measurement signals has to be acquired. In this work we present a comparative analysis of the two approaches, which is based on measurement experiments and a holistic system model for flow metering. For the model-based analysis Monte Carlo simulations are conducted, where randomly generated pneumatic conveying flow patterns are simulated to analyze the sensor and algorithm behavior. The results demonstrate the potential benefit of electrical capacitance tomography based flow meters over a calibration-based instrument design.

Uncertainty Analysis of an Optoelectronic Strain Measurement System for Flywheel Rotors.

The strain in a fast spinning carbon fiber flywheel rotor is of great interest for condition monitoring, as well as for studying long-term aging effects in the carbon fiber matrix. Optoelectronic strain measurement is a contactless measurement principle where a special reflective pattern is applied to the rotor which is scanned by a stationary optical setup. It does not require any active electronic components on the rotor and is suited for operation in a vacuum. In this paper, the influences of the key parts comprising the optoelectronic strain measurement are analyzed. The influence of each part on the measurement result including the uncertainty is modeled. The total uncertainty, as well as each part's contribution is calculated. This provides a valuable assessment of requirements for component selection, as well as tolerances of mechanical parts and processes to reach a final target measurement uncertainty or to estimate the uncertainty of a given setup. We have shown that the edge quality of the special reflective pattern has the strongest influence, and how to improve it. Considering all influences, it is possible to measure strain with an uncertainty of less than 1% at a rotation speed of 500Hz.