Sensor Device and Method for Predicting a Damage State of Components

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This patent describes a sensor device and associated method for detecting and predicting the damage state of various components (such as those made from ceramic, metal, glass, or fiber composites) during operation. It works by capturing and analyzing emissions (light, radiowaves, electrons) that occur in pulses as microcracks form and propagate within materials. The sensor measures both the intensity and number of these emissions, using specialized filters, to determine the number and width of microcracks, thereby quantifying damage and allowing for real-time assessment and prediction of material failure.

Use CasesContent extracted from patent full text and abstract with AI.

• Continuous, online monitoring of structural health in critical engineering structures (e.g., bridges, buildings, tunnels).
• Early damage detection in aviation, automotive, naval, and military mechanical parts to prevent catastrophic failures.
• Real-time condition monitoring of elevators, escalators, and industrial machinery for maintenance optimization.
• Predictive assessment of wear and failure in medical implants such as prosthetics.
• Non-destructive testing of consumer electronics and appliances during manufacturing or service life.
• Monitoring of seismic or geotechnical structures for early warning of earthquakes or landslides.
• Scientific research applications for studying crack formation in materials science, including brittle or composite materials.
• Online quality control in manufacturing environments for ceramics, glass, and metals.

BenefitsContent extracted from patent full text and abstract with AI.

• Enables non-destructive, real-time, and online damage detection without interrupting operation or requiring disassembly.
• Accurately quantifies both the number and size of microcracks, giving a more complete assessment of component health.
• Not limited to specific materials—can be used across a wide range of substrates, increasing its versatility.
• Allows timely prediction of component failure, enhancing safety and reducing unexpected downtime.
• Reduces maintenance and inspection costs by identifying actual damage states instead of relying on scheduled replacements.
• Supports proactive, condition-based maintenance strategies, which can extend component lifetimes.
• Can be implemented in a wide variety of applications, potentially including medical, industrial, civil engineering, and consumer products.

Technical Classifications (CPCs)

Inventors & Applicants

Patent Abstract

The invention relates to a sensor device (1) for ascertaining and predicting a damage state of components in operation, said components preferably consisting of ceramic, metal, glass, or fiber composite materials, on the basis of a fracto-emission in the form of a light, radiowave, or electron emission, consisting of pulses, during the formation and spreading of microcracks. The sensor device (1) comprises at least - two channels (5), and - one filter (4), preferably a near-infrared filter, UV filter, electronic filter, or electric voltage filter, said damage state being ascertainable from the product of the width of microcracks and the number of microcracks based on the spectral intensity and based on the number of the fracto-emission pulses.