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Passive Digital Sensing Method and Its Implementation on Passive RFID Temperature Sensors

Benefitting from the advancement of digital electronics in the 20 th century, sensors have also gradually evolved from analog to digital. As semiconductor components are required in digital sensors, a power supply is still needed for the sensor. To eliminate the need for a power supply a concept of passive digital sensing is proposed. Different from the semiconductor-based electrical digital sensing method, the parameter to be measured is first converted to a mechanical signal, then the mechanical signal is encoded to multiple digital bits by a passive digitizer, where each bit is identified as open or short state that is detectable by general IO ports. To demonstrate the proposed sensing concept, a passive RFID temperature sensor is implemented using a bimetallic coil as the temperature sensing unit. The 6-bit binary codes are acquired and transmitted by a passive RFID that is powered by an energy harvester. Furthermore, the test results show that the temperature sensor has a measurement sensitivity of 1.32 °C/bit and a working distance over 10 meters.

47 OTHER INSTRUMENTATION↗

All-Digital Plug and Play Passive RFID Sensors for Energy Efficient Building Control

This is the final report for the project “All-Digital Plug and Play Passive RFID Sensors for Energy Efficient Building Control”, funded by DOE, and performed by Clemson University, Phase IV Engineering and Harvard University from October 1, 2016 to December 31, 2020. The main objective of this project is to develop, demonstrate and pre-commercialize a novel, plug & play, battery-free, wireless sensor technology to enable low-cost (<$10 per node) indoor and outdoor temperature and humidity measurement for energy efficient building controls and operations. The proposed technology is based on the novel concept of all-digital sensing and its seamless integration with the passive RFID technology. This project focuses on the design, fabrication, material optimization, interrogation electronics, validation, and demonstration of the novel sensor nodes for building applications. The specific objectives of this research program include: (1) Design, fabricate and optimize a compact, robust, and high-resolution digitizer, which could convert rotation angle into digital numbers. (2) Develop the multi-physics-based modeling and simulation of the temperature/humidity transducer to derive a rational design of the architecture, dimension, structure, materials (i.e., mechanical, electrical, thermal and hygroscopic) properties and functions of the sensor node. (3) Design, fabricate and optimize the bi-material based humidity sensitive coil which could linearly transduce the environmental relative humidity variations to rotation angles. (4) Design, fabricate and optimize an UHF RFID platform which could support long-range passive wireless communications of 8-bit digital numbers. (5) Design, fabricate and optimize the miniaturized all-digital sensor using MEMS technology. (6) Validate the integrated all-digital sensing system in a real building environment to test the system’s performance.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

Passive Wireless Sensors for Realtime Temperature and Corrosion Monitoring of Coal Boiler Components Under Flexible Operation (Final Technical Report)

Researchers at West Virginia University (WVU) propose to demonstrate inexpensive wireless, high-temperature sensors for real-time monitoring of the temperature and corrosion of metal components, which are commonly used in coal-fired boilers. This study presents the development of cost-effective wireless high-temperature sensors for real-time temperature and corrosion monitoring in coal-fired boilers' metal components. The focus is on fabricating and evaluating chipless radio-frequency identification (RFID) sensors capable of operating between 25-1300 ºC. Efforts were directed towards designing passive RFID sensor and interrogator antenna with a broad frequency range, optimizing a microstrip patch antenna sensor integrated into a "peel-and-stick" format for efficient application to various metal specimens without altering their geometry. Additionally, this research aimed to assess the sensor responses under accelerated high-temperature conditions, correlating corrosion and cracking mechanisms with sensor data. An investigation of through-wall data acquisition techniques was also planned, facilitating unobtrusive monitoring of sensor responses housed within metal enclosures. Ultimately, this work sought to establish a robust passive wireless sensor system for the continuous health monitoring of metal components in operational settings, thereby contributing to enhanced safety and efficiency in coal-fired power plants.

20 FOSSIL-FUELED POWER PLANTS↗

Integration of Wireless Sensor Networks and Battery-free RFID for Advanced Reactors

To address an important need for Nuclear Power Plants (NPPs) to significantly reduce the amount of the required cables for sensor data communications, this Phase I SBIR effort successfully developed and demonstrated a novel low-cost proof-of-concept prototype of a secure wireless sensor network backbone communications system. This system combines commercially available low power, low cost XBEE wireless communications network and passive (battery-free) Radio Frequency Identification (RFID) systems to report individual sensor data and their location through the containment wall for rapid response to anomalies in nuclear facilities. This WIreless Sensing and Locating (WISLO) system network architecture allows non-intrusive wireless collection of sensor data with the sensor’s accurate location information from inside of the instrumentation or containment area with minimal need for power sources. The multi-node sensor data in the containment area is wirelessly transmitted to outside through the metal reinforced concrete walls without the need for any batteries. The WISLO system could be readily used in current reactor fleet and future advanced reactors, as well as in small modular reactors (SMR). The WISLO system is the first dual frequency battery-free trough the wall communications backbone system developed specifically for use in nuclear power plants. It not only can modernize the sensor monitoring practices in the existing reactor fleet, but also offers a secure, low-cost solution to advanced reactors and SMRs by removing cables and issues related to them such as cable integrity, reporting delays, and installation and maintenance costs. The intent is to improve process safety, reliability, efficiency, and cost effectiveness to the monitoring and maintenance process in current and future plants. As we address the next productization and manufacturing capabilities in the next phase, this system will serve the needs of many commercial and government applications in remote monitoring of sensor data that demand battery-free transmission of sensor data such as Internet-of-Things (IOT).

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

Thin Film Hydrogen Sensor Development, Testing and Integration Into Low Cost Wireless Sensing Systems (SBIR Phase 1 Final Report)

Element One, Inc. is reporting on the results of its DOE SBIR Phase I project for the development and testing of low-cost thin film hydrogen sensors and their subsequent integration into wireless sensing systems and networks. This work is based on Element One’s chemo-chromic sensing technology which indicates hydrogen presence (leaks) colorimetrically and electronically with no power required. The lack of required power makes them particularly suitable for passive Radio Frequency Identification Device (RFID) technology which can be deployed affordably and abundantly to detect leaks in hazardous environments. Element One built upon its experience with chemochromic materials that change color in the presence of hydrogen. Both thin films and pigments have been used, but thin films have the ability to change conductivity by more than three orders of magnitude making them ideal for resistive sensors. Prototype sensors were fabricated, tested and characterized. For the wireless component, Element One partnered with Esensor, Inc. to construct and test a wireless sensing network. The network was tested and validated at the National Renewable Energy Laboratory (NREL) in February and March. The tests involved exposing the wireless system to hydrogen gas concentrations of 1% and 5%. There were no significant problems encountered, and the system is ready for commercial development. The system demonstrated the viability of wireless hydrogen sensing networks for hydrogen leak detection and other applications.

08 HYDROGEN↗

Loop Antennas for Use On/Off Ground Planes

Many applications benefit from the ability of an RFID tag to operate both on and off a conducting ground plane. This paper presents an electrically small loop antenna at 433 MHz that passively maintains its free-space tune and match when located a certain distance away from a large conducting ground plane. The design achieves this using a single radiation mechanism (that of a loop) in both environments without the use of a ground plane or EBG/AMC structure. An equivalent circuit model is developed that explains the dual-environment behavior and shows that the geometry balances inductive and capacitive parasitics introduced by the ground plane such that the free-space loop reactance, and thus resonant frequency, does not change. A design equation for balancing the inductive and capacitive parasitic effects is derived. Finally, experimental data showing the design eliminates ground plane detuning in practice is presented. The design is suitable for active, “hard” RFID tag applications.

42 ENGINEERING↗

All-Ceramic Passive Wireless Temperature Sensor Realized by Tin-Doped Indium Oxide (ITO) Electrodes for Harsh Environment Applications

In this work, an all-ceramic passive wireless inductor–capacitor (LC) resonator was presented for stable temperature sensing up to 1200 °C in air. Instead of using conventional metallic electrodes, the LC resonators are modeled and fabricated with thermally stable and highly electroconductive ceramic oxide. The LC resonator was modeled in ANSYS HFSS to operate in a low-frequency region (50 MHz) within 50 × 50 mm geometry using the actual material properties of the circuit elements. The LC resonator was composed of a parallel plate capacitor coupled with a planar inductor deposited on an Al2O3 substrate using screen-printing, and the ceramic pattern was sintered at 1250 °C for 4 h in an ambient atmosphere. The sensitivity (average change in resonant frequency with respect to temperature) from 200–1200 °C was ~170 kHz/°C. The temperature-dependent electrical conductivity of the tin-doped indium oxide (ITO, 10% SnO2 doping) on the quality factor showed an increase of Qf from 36 to 43 between 200 °C and 1200 °C. The proposed ITO electrodes displayed improved sensitivity and quality factor at elevated temperatures, proving them to be an excellent candidate for temperature sensing in harsh environments. The microstructural analysis of the co-sintered LC resonator was performed using a scanning electron microscope (SEM) which showed that there are no cross-sectional and topographical defects after several thermal treatments.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Indoor Occupant Counting by RF Backscattering

Building HVAC (heating, ventilation and air conditioning) consumes approximately 13% of all energy consumption in USA. Motion detectors, cameras and user programmable thermostats have been shown to be ineffective for HVAC controls to save energy, mostly due to the user concerns of comfort, reliability and privacy. A new HVAC control system based on real-time occupant counting that is fully automated, highly accurate, economically sensible and preserving privacy and aesthetics can thus bring forth a disruptive impact to this large energy sector. Our indoor occupant monitoring technology is based on the radio-frequency identification system (RFID), deployed in the room, not on the occupants. One reader with four antennas can be deployed on the ceiling or behind the ceiling panels for every thousand square feet in home, office and assisted living, with or without room partitions. The sticker-like passive tag, 10 cents each and maintenance-free, are profusely hidden on the wall or inside the furniture at arbitrary position, preserving privacy and aesthetics. The large number of tags can realize diverse observation points to accommodate arbitrary room layouts, which is impractical by other active units of camera, infrared, radar or lidar. With 20 tags, the system can reliably detect the number of occupants. For 100 tags, occupant posture and location can be known. The technology has been verified in the research labs and test buildings with very high accuracy. When the real-time occupant number can be accurately known without assuming devices on occupants or occupant motion, the building HVAC system can be automated to achieve building energy saving without sacrificing occupant comfort. According to our limited testing in a few types of building models and the simplified cost calculation, the RFID system has low overall cost in production, deployment, operation and maintenance. The signal processing algorithm based on machine learning requires very small number of training cases as most learning is transferrable for various layouts, and very low computational needs during operation, according to our testing in four different room sizes and layouts. In our preliminary estimate from HVAC saving alone, the RFID system can potentially pay for itself within 1.5 years, in addition to the other enhancement in building automation systems (BAS). Our commercialization strategy and business pitch deck focus on venturing this Cornell occupant monitoring technology into BAS and energy management markets. We have identified three broad BAS market segments of senior living, residential buildings, and office buildings. We have put together the minimum viable product characteristics for these identified segments, including analyses on total cost and competing technologies, as well as the fit and technical gaps for these market segments. We intend to bring the technology to market by licensing or partnering with existing BAS vendors. A list of potential collaborators and licensing partner candidates was assembled for different aspects of integrating our technology into a potential product that can be used with BAS.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗