Sensor Device and Method for Detecting and Localising Cracks in Components

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This patent discloses a sensor device and method for detecting and localizing cracks, including micro-cracks, in components—especially those made from electrically conductive plastics or fiber-reinforced composites. The invention is based on applying an electrical voltage to the component, which induces the emission of radio and/or microwaves when a crack forms or propagates. Specialized sensors then detect these emissions in a wide frequency range (16 kHz to 100 GHz), enabling contactless, real-time crack detection and localization, even during operation or through barriers.

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

• In-situ (online) monitoring of structural integrity in aircraft components to detect cracks before catastrophic failure.
• Damage assessment and maintenance planning for automotive and railway vehicle parts made of conductive composites.
• Safety verification and longevity prediction in wind turbine blades, elevators, or ships incorporating fiber-reinforced polymer parts.
• Inspection of critical infrastructure such as bridges and buildings, especially in earthquake-prone regions.
• Testing of medical devices and sports equipment (e.g., bicycles, skis) for internal cracks without disassembly.
• Rapid, non-destructive quality control in manufacturing lines for conductive composite products.

BenefitsContent extracted from patent full text and abstract with AI.

• Enables early, non-destructive detection of both macro- and micro-cracks, improving safety and reliability.
• Can be used for real-time, contactless, and online monitoring during component operation or in hard-to-reach locations.
• Reduces downtime and maintenance costs by eliminating the need for disassembly for many inspections.
• Allows precise localization and sizing of cracks, supporting targeted repairs and life-cycle management.
• Applicable through barriers and at a distance (up to 1000 meters), with robustness against electromagnetic interference.
• Adaptable for both stationary and portable use, and suitable for a broad range of industrial, medical, and safety applications.

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Inventors & Applicants

Patent Abstract

The present invention relates to a device and a method for detecting cracks and crack formation processes in components, preferably electrically conductive plastic components, on the basis of inducing and receiving radio and/or microwaves during the appearance and propagation of cracks and/or micro-cracks, or in existing cracks in a component.