Flexible sensors relay vital measurements
Greg Reed, Contributing Technical Editor -- Test & Measurement World, 11/9/2006 4:18:00 PM
In a search for innovative new products, I discovered the Bend Sensor from Flexpoint Sensor Systems. This product measures mechanical movement, air flow, water flow, and vibration. It is mounted on a flexible substrate such as plastic, and it changes in electrical conductivity as it is bent.
For protection in harsh environments, such as automotive or aerospace applications, over-molded laminates seal out dirt, liquids, heat, and pressure to extend durability. I recently interviewed Tom Danielson, engineering product manager at Flexpoint, to learn more about the Bend Sensor.
Q: Which automotive and aerospace applications are best suited for the sensor?
A: The Bend Sensor measures deflection and movement. Therefore, any application in the automotive or aerospace industries that involves a material or apparatus that moves would be a potential application for this technology. Some examples would include bumper-impact detection, side-impact detection, occupant detection in the seat, horn sensors, and various switches throughout the vehicle.
Q: How do you measure deflection, acceleration, range of motion, vibration, and other mechanical phenomena?
A: These sensors can be attached, or molded into, any item that requires measurement. Once they are placed, we can then measure the movement of the application by monitoring the amount of change in the resistance value of the sensors. We also monitor the rate of change in the resistance values of the sensors. By measuring the amount of change and the rate of change in a sensor's resistance value, we are able to determine range of motion, velocity, acceleration, vibration, or simply activation.
Q: What special harsh environment challenges must be overcome when conducting test procedures for auto/aero applications?
A: The automotive and aerospace industries require rigorous testing. Designs must pass testing at extreme temperatures, extreme humidity levels, and pressure changes, and they must endure large numbers of actuations that are sometimes in abrasive environments. In addition, they must withstand exposure to a variety of liquids and still be able to function.
Q: What electronic systems interfaces are incorporated into your products?
A: We designed a data-acquisition board that can test up to 30 Bend Sensors at a time. Engineers can choose the sampling rate for the recording of data to meet the needs of the test setup that works best for a particular application. Effectiveness has been proven for life-cycle testing, durability testing, and environmental testing, as well as application layout and design.
Q: What solutions do flex polyimide and laminate substrates provide?
A: Bend Sensors are printed onto a 5-mil-thick polyimide substrate and can be molded into plastic and rubber materials in various shapes and sizes. For most automotive or aerospace applications, we recommend over lamination with a 1-mil-thick polyimide material to ensure performance through a wide variety of environments.
In this mode, the sensors can detect and measure the movement of air, water, harsh liquids, and a wide variety of mechanical movements. The ability to withstand temperature extremes, a wide range of liquids, pressure fluctuations, and dirty dusty environments through greater than 30 million cycles has been demonstrated.
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