Embedded sensor marine mining hose monitoring system, method of manufacture and monitoring method

Abstract

The present application relates to a kind of embedded sensing ocean mining hose monitoring system, manufacturing method and monitoring method, including acoustic sensor, sensor base and corresponding multilayer structure combination pipe, the pipe lining layer is used to transport marine mineral fluid medium, the acoustic sensor is embedded in the base, the base is installed on the outside of the lining layer, so that the acoustic sensor monitors the medium fluid flow in lining layer and the operating state of pipe itself.The present application embeds acoustic sensor in the base compared with prior art, then the base is installed on the outside of the lining layer, when marine mineral fluid medium is transported in the pipe of hose body, the acoustic sensor is not damaged, to achieve monitoring the medium fluid flow in lining layer and the operating state of pipe itself in non-invasive destructive manner, while ensuring the integrity of the pipe in hose, improve the monitoring stability of the fluid in the pipe of ocean mining hose.

Description

Technical Field

[0001] This invention relates to the field of marine mining technology, and in particular to a marine mining hose monitoring system with embedded sensors, its manufacturing method, and its monitoring method. Background Technology

[0002] Marine minerals are diverse and abundant. Marine mining is a complex system engineering project integrating multiple disciplines, high technologies, and fields. Currently, marine mining hoses are typically rubber pipes or other composite pipes used to transport mineral media. Ordinary rubber pipes typically cannot monitor the internal fluid flow during use, while other composite pipes, which directly mount monitoring devices on the outside, are easily damaged during use, further hindering monitoring of the internal fluid flow and the pipe's operational status. Summary of the Invention

[0003] The purpose of this invention is to overcome the shortcomings of the prior art by providing an embedded sensor-based marine mining hose monitoring system, manufacturing method, and monitoring method.

[0004] The objective of this invention can be achieved through the following technical solutions:

[0005] According to the present invention, a marine mining hose monitoring system with embedded sensors is characterized in that it includes an acoustic sensor, a base, and a tubular inner liner. The inner liner is used to transport marine mineral fluid media. The acoustic sensor is embedded in the base, and the base is installed on the outside of the inner liner, so that the acoustic sensor can monitor the flow of the medium fluid in the inner liner and the operating status of the pipeline itself.

[0006] Compared with the prior art, the present invention embeds the acoustic sensor in the base and then installs the base on the outside of the inner liner. When the marine mineral fluid medium is transmitted in the pipe of the hose body, the acoustic sensor will not be damaged. It realizes the monitoring of the fluid flow in the inner liner and pipe of the hose and the operating status of the pipe itself in a non-invasive and destructive manner, while ensuring the integrity of the internal pipe of the hose and improving the monitoring stability of the fluid inside the marine mining hose.

[0007] Preferably, the base is ring-shaped, and multiple acoustic sensors are provided, with the multiple acoustic sensors distributed circumferentially along the circumferential direction of the base, so that the acoustic sensors and the base together form a monitoring ring.

[0008] Preferably, at least two bases are provided, and the plurality of bases are spaced apart along the pipe length direction of the inner liner, so that the plurality of acoustic sensors are arrayed along the pipe length direction of the inner liner; the outer side of the inner liner is filled between adjacent bases by a polymer sheath layer, and the bases and the polymer sheath layer together form a monitoring functional layer.

[0009] Compared with the prior art, the present invention can accurately position the acoustic wave sensor by placing the acoustic wave sensor on the base and filling the gap between the bases with a monitoring sheath layer.

[0010] Preferably, the monitoring system further includes an armor reinforcement layer, which is disposed on the outside of the monitoring functional layer, and the armor reinforcement layer is formed by an even number of armor threads wound in a 20-60° range.

[0011] Preferably, the armor reinforcement layer is configured as multiple layers, and the monitoring system also includes an armor abrasion-resistant layer, which is disposed between adjacent armor reinforcement layers and on the outside of the outermost armor reinforcement layer.

[0012] Preferably, the armor abrasion-resistant layer is formed by integral extrusion coating;

[0013] The monitoring system also includes an outer sheath layer, which is placed outside the outermost armored abrasion layer.

[0014] Preferably, the inner lining layer includes a wear-resistant layer and an outer material layer arranged from the inside out;

[0015] And / or, the monitoring system also includes a signal transmission cable connected to an acoustic sensor, the signal transmission cable being wound around the outside of the inner lining.

[0016] Preferably, the inner side of the base and the inner side of the polymer sheath layer are on the same surface, and the outer side of the base and the outer side of the polymer sheath layer are on the same surface.

[0017] According to the present invention, a method for manufacturing an embedded sensing marine mining hose monitoring system is provided for manufacturing the above-mentioned embedded sensing marine mining hose monitoring system, comprising: the base and the polymer sheath layer are embedded in the same layer and extruded and encapsulated on the outside of the inner liner layer, so that the inner side of the base and the inner side of the polymer sheath layer are extruded and connected to the same surface, and the outer side of the base and the outer side of the polymer sheath layer are extruded and connected to the same surface.

[0018] According to the present invention, a method for monitoring marine mining hoses with embedded sensors is provided, using any of the above-described marine mining hose monitoring systems with embedded sensors, comprising: embedding an acoustic sensor in the base, installing the base on the outside of the inner lining, and monitoring the flow of the medium fluid in the inner lining and the operating status of the pipeline itself through the acoustic sensor. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the overall structure of the wear-resistant inner lining layer of the present invention;

[0020] Figure 2 This is a schematic diagram of the acoustic wave sensor array monitoring ring device of the present invention;

[0021] Figure 3 This is a schematic diagram of the assembly of the monitoring device (with two sets of monitoring rings) of the present invention after it is embedded in the hose structure;

[0022] Figure 4 This is a schematic diagram of the combination of a single sensor monitoring ring and a hose intermediate sheath according to the present invention;

[0023] Figure 5 This is a schematic diagram of the combination of the sensor monitoring ring and the intermediate sheath layer of the hose in this invention;

[0024] Figure 6 This is a schematic diagram of a single reinforcing tensile steel wire according to the present invention;

[0025] Figure 7 This is a schematic diagram of the armored reinforced hose structure of the present invention;

[0026] Figure 8 This is a schematic diagram of the armored wear-resistant layer arrangement structure of the present invention;

[0027] Figure 9 This is a schematic diagram of the overall structure of the hose of the present invention.

[0028] Reference numerals: 1. Wear-resistant layer; 2. Outer material layer; 4. Base; 5. Acoustic sensor; 6. Signal transmission cable; 7. Monitoring ring; 8. Polymer sheath layer; 9. Armor reinforcement layer; 10. Armored wear-resistant layer; 11. Outer sheath layer; 12. Armored line. Detailed Implementation

[0029] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments. These embodiments are based on the technical solution of the present invention and provide detailed implementation methods and specific operating procedures. However, the scope of protection of the present invention is not limited to the following embodiments.

[0030] Through in-depth research and improvement exploration of marine mining hoses, the applicant discovered that: conventional marine mining hoses cannot monitor the blockage status of fluid flow and the content of solid particles inside the pipe during use, and are limited by the vulcanization process of the rubber pipe itself, making it impossible to process large-diameter and long pipes. At the same time, other composite pipes are also unable to achieve effective erosion and wear protection and fluid information monitoring of the internal fluid medium due to their own material and structural limitations.

[0031] Based on this, the technical solutions provided by the various embodiments of this application will be described below with reference to the accompanying drawings.

[0032] This specification presents an embodiment of a marine mining hose monitoring system with embedded sensors, such as... Figure 2 , Figure 3 As shown, the device includes an acoustic sensor 5, a base 4, and a tubular inner liner. The inner liner forms a complete sealed pipe and is used to transport marine mineral fluid media. The acoustic sensor 5 is embedded in the base 4, which is installed on the outside of the inner liner, so that the acoustic sensor 5 can monitor the flow of the medium fluid in the inner liner and the operating status of the pipe itself, such as monitoring the health status of the pipe inner liner.

[0033] In one embodiment, such as Figure 3 As shown, the base 4 is ring-shaped, and multiple acoustic sensors 5 are arranged in a circular combination along the circumference of the base 4, so that the acoustic sensors 5 and the base 4 together form a monitoring ring 7. This enables omnidirectional monitoring of the marine mining hose.

[0034] In one embodiment, at least two bases 4 are configured in combination, and multiple bases 4 are spaced apart along the pipe length direction of the inner liner, so that multiple acoustic sensors 5 are arrayed along the pipe length direction of the inner liner. Adjacent bases 4 on the outer side of the inner liner are filled with a polymer sheath layer 8. The bases 4 and the polymer sheath layer 8 together form a monitoring functional layer, also known as a monitoring protection layer. Multiple acoustic sensors 5 can be arrayed and combined along the circumference and length direction of the pipe in the inner liner to form a sensor array. The bases 4 and the polymer sheath layer 8 are embedded in the same layer and extruded and encapsulated on the outer side of the inner liner, so that the bases 4 and the polymer sheath layer 8 together form a monitoring functional layer, and the marine mining hose monitoring system is formed from the inside out. Both the bases 4 and the polymer sheath layer 8 can be made of polymers such as polyethylene, polypropylene, and polyamide. The bases 4 and the polymer sheath layer 8 are simultaneously extruded and connected. The sensor array is arranged circumferentially on the outer side of the inner liner based on the Doppler effect principle. By measuring the difference between the transmission frequency and the reception frequency, information such as the flow rate and velocity inside the hose can be obtained.

[0035] The polymer sheath layer 8 can also be formed on the two mutually spaced sides of the base 4. The base 4 is a polymer base with grooves or holes for mounting the acoustic wave sensors 5. The array spacing of the acoustic wave sensors 5 is determined according to the inner and outer diameters of the marine mining hose and the different mineral media. The monitoring and protection layer is a sensor array monitoring intermediate sheath layer formed by embedding the acoustic wave sensor 5 array and the polymer in the same layer and extruding and encapsulating them. The focus of this layer is to protect and position the sensor array. Adding an intermediate sheath layer to this layer allows the sensor array to be embedded into the hose structure as a whole, while also improving the overall bending and torsional resistance of the hose and preventing damage to the underwater mining vehicle during bending and rotation operations.

[0036] The base sensing devices are arranged individually or in pairs on the outside of the pipe lining. The flow rate, velocity and distribution of solid particles in the pipe are monitored by the sound velocity difference of the acoustic sensors 5 arranged in an array along the pipe direction of the lining. A single base sensing device can be used to monitor pipe wall erosion and wear at a specific location in the pipe.

[0037] In one embodiment, such as Figure 6 and Figure 7 As shown, the monitoring system also includes an armor reinforcement layer 9, which is disposed on the outside of the monitoring function layer, and the armor reinforcement layer 9 is formed by an even number of armor lines 12 wound in a 20~60° range.

[0038] The reinforcing armor layer is located outside the middle sheath layer of monitoring ring 7. It consists of two or more layers (even-numbered layers) of armored steel wire (round or flat) or armored tape, wound in both directions (clockwise and counterclockwise), typically within a ±20~±60° range. It is mainly used to enhance the axial tensile strength of the hose and increase its axial pull. When considering hose weight and tensile strength, a combination of metal and fiber can be used, such as an inner fiber layer and an outer metal layer. This can effectively reduce manufacturing costs while ensuring the overall tensile performance of the hose. The forward and reverse winding layers alternate, with the forward winding layer serving as the inner or outer layer of even-numbered layers, and vice versa. For example, the inner layer of even-numbered layers may use fiber, and the outer layer may use metal.

[0039] In one embodiment, the armor reinforcement layer 9 is configured as a single layer or a combination of multiple layers. The monitoring system also includes an armor abrasion-resistant layer 10, which is disposed between adjacent armor reinforcement layers 9 and on the outermost armor reinforcement layer 9. The armor abrasion-resistant layer 10 is made of high-toughness polyester or polyamide material and is formed by extrusion coating or strip winding, mainly used for abrasion protection of adjacent armor layers of the hose.

[0040] In one embodiment, the armored abrasion layer 10 is formed by integral extrusion coating; the monitoring system also includes an outer sheath layer 11, which is placed outside the outermost armored abrasion layer 10. The outer sheath layer 11 is mainly extruded from a polymer material, typically polyurethane, polyethylene, or polyamide nylon, and its main function is to provide a seal for the hose and protection against external impact and abrasion.

[0041] The inner lining is composed of two or more polymer materials, including a wear-resistant layer 1 and a first outer material layer, a second outer material layer, etc., from the inside to the outside. The first outer material layer and the second outer material layer are both called outer material layer 2. The wear-resistant layer 1 uses wear-resistant PVDF (polyvinylidene fluoride) or PA (polyamide) and PP (polypropylene) materials as the innermost wear-resistant layer, serving as the first inner lining layer. The outer layer is composed of HDPE (high molecular weight polyethylene) or other polymers. This layer is processed in a multi-layer conformal manner.

[0042] This conformal design focuses on reducing the impact and wear of internal solid particles on the hose liner during transport. It also utilizes a combination of multiple polymers to effectively reduce the high cost of single polymers. The innermost layer is typically nylon or PVDF (polyvinylidene fluoride) and other fluorinated wear-resistant layers, with a thickness of approximately 2-3 mm. The outer layer, such as polyethylene, has an optimal thickness of around 5 mm, which is considered economical. The thickness of each layer can be adjusted according to actual conditions. The unique feature of this composite structure is its multi-layer conformal molding of different materials, effectively reducing the risk of delamination and separation in traditional multi-layer structures. Simultaneously, it significantly improves the hose's internal durability and overall structural strength.

[0043] And / or, the monitoring system also includes a signal transmission cable 6 connected to the acoustic sensor 5, which is wound around the outside of the inner liner. The signal transmission cable 6 is the cable for the monitoring ring 7. The sensor cable is made of high-temperature resistant PI-protected cable with high tensile strength to avoid armor wear and high-temperature heat-fusion failure during production. The cable is wound around the outside of the inner liner, which effectively reduces the stress load on the cable when the hose is bent, stretched, and twisted. The signal transmission cable 6 is covered by a polymer sheath layer 8 and is located between the inner liner and the monitoring protection layer.

[0044] In one embodiment, such as Figure 4 and Figure 5 As shown, the inner surface of the base 4 and the inner surface of the polymer sheath layer 8 are on the same side, and the outer surface of the base 4 and the outer surface of the polymer sheath layer 8 are on the same side. The middle sheath layer of the sensor array has the same size (inner and outer diameter) as the sensor monitoring ring 7, and its purpose is to encapsulate the monitoring ring 7. Its material is the same as that of the base 4 of the sensor monitoring ring 7, and its purpose is to reduce the signal edge scattering and distortion effect of the acoustic sensor 5.

[0045] This invention provides a marine mining hose that simultaneously possesses wear resistance and internal fluid monitoring capabilities. It enables monitoring of fluid flow blockage and solid particle content within the pipeline, facilitating the fabrication of continuous, long-length pipelines of varying diameters, while simultaneously improving the pipeline's resistance to erosion and wear. Structurally, the hose comprises at least the following layers, from the inside out: a polymer composite inner liner, a sensor array monitoring and intermediate sheath layer, an axial tensile armor reinforcement layer 9, a polyester wear-resistant layer (between adjacent armor layers and outside the outermost armor layer), and a polymer outer sheath layer 11. The sensor array device consists of a polymer base 4, sensors, and signal transmission cables 6.

[0046] The manufacturing process of the hose proceeds from the inside out. First, a multi-layered composite inner liner is produced using a conformal method. Next, monitoring sensors are pre-positioned at predetermined monitoring locations within the inner liner. The sensors and their cables are then embedded and fixed in their designated positions on the outside of the inner liner. Next, the intermediate sheath layer is extruded and coated. Then, the armor reinforcement layer 9 and the wear-resistant layer are wound together. The wear-resistant layer can be manufactured using either integral extrusion coating or strip winding, depending on the specific requirements. When using strip winding, a near-90° angle is preferred to improve the wrapping and stability after winding. Finally, the outer sheath layer 11 is produced using an extrusion coating process, thus completing the final forming of this marine mining hose.

[0047] This invention discloses an online monitoring method for a marine mining hose monitoring system with embedded sensors. This method integrates a sensor array into the hose structure to achieve real-time online monitoring of the flow state of the fluid medium used for transporting minerals on the seabed. Specifically, the sensor array is embedded in the hose's intermediate sheath layer and arranged outside the wear-resistant inner lining layer. It consists of two or more arrays of acoustic sensors (5), used to continuously collect parameter data such as flow rate and velocity of the medium inside the hose.

[0048] This specification also discloses a method for manufacturing an embedded sensor marine mining hose monitoring system. The method includes: a base 4 and a polymer sheath layer 8 are embedded in the same layer and extruded and encapsulated on the outside of the inner liner layer, so that the inner side of the base 4 and the inner side of the polymer sheath layer 8 are extruded and connected to the same surface, and the outer side of the base 4 and the outer side of the polymer sheath layer 8 are extruded and connected to the same surface.

[0049] This specification also discloses a method for monitoring marine mining hoses with embedded sensors. Using any of the aforementioned marine mining hose monitoring systems with embedded sensors, the method includes: embedding an acoustic sensor 5 into a base 4, installing the base 4 on the outside of the inner lining layer, and monitoring the flow of the medium fluid in the inner lining layer and the operating status of the pipeline itself using the acoustic sensor 5. The monitoring device is typically installed in pairs, using the sound velocity difference of the acoustic sensors 5 arrayed along the pipeline direction of the inner lining layer to monitor the flow rate, velocity, and internal solid particle distribution of the medium fluid in the pipeline. Alternatively, a single pair can be used to monitor erosion and wear at specific locations.

[0050] The overall structure of the hose serves as the method carrier, comprising, from the inside out: a wear-resistant inner liner (using a multi-layer conformal process to improve wear resistance and reduce cost), an intermediate sheath layer (embedded with a sensor array), an axial tensile-reinforced armor layer (composed of steel wire or high-modulus fiber material, providing tensile strength to the hose body), a polyester fiber or polymer wear-resistant layer, and an outer sheath layer 11 (extruded from polymers such as polyethylene or polyurethane, used for isolation and protection). The core of this method lies in utilizing an embedded sensor array to achieve non-invasive online monitoring, while simultaneously employing a multi-layer conformal approach to enhance the hose's wear resistance, significantly improving the operational safety and efficiency of marine mining hoses.

[0051] The preferred embodiments of the present invention have been described in detail above. It should be understood that those skilled in the art can make numerous modifications and variations based on the concept of the present invention without creative effort. Therefore, all technical solutions that can be obtained by those skilled in the art based on the concept of the present invention through logical analysis, reasoning, or limited experimentation on the basis of existing technology should be within the scope of protection defined by the claims.

Claims

1. A marine mining hose monitoring system with embedded sensors, characterized in that, The device includes an acoustic sensor, a base, and a tubular inner liner for transporting marine mineral fluid media. The acoustic sensor is embedded in the base, which is mounted on the outside of the inner liner, so that the acoustic sensor can monitor the flow of the fluid media in the inner liner and the operating status of the pipeline itself.

2. The marine mining hose monitoring system with embedded sensors according to claim 1, characterized in that, The base is configured as a ring, and multiple acoustic sensors are configured, with the multiple acoustic sensors distributed circumferentially along the ring direction of the base, so that the acoustic sensors and the base together form a monitoring ring.

3. The marine mining hose monitoring system with embedded sensors according to claim 2, characterized in that, The base is provided in at least two parts, and the plurality of bases are distributed at intervals along the pipe length direction of the inner liner, so that the plurality of acoustic sensors are arrayed along the pipe length direction of the inner liner; the outer side of the inner liner is filled between adjacent bases by a polymer sheath layer, and the bases and the polymer sheath layer together form a monitoring functional layer.

4. The marine mining hose monitoring system with embedded sensors according to claim 3, characterized in that, The monitoring system also includes an armor reinforcement layer, which is disposed on the outside of the monitoring functional layer, and is formed by an even number of armor lines wound in a 20-60° range.

5. The marine mining hose monitoring system with embedded sensors according to claim 4, characterized in that, The armor reinforcement layer is configured as multiple layers, and the monitoring system also includes an armor abrasion-resistant layer, which is disposed between adjacent armor reinforcement layers and on the outside of the outermost armor reinforcement layer.

6. The marine mining hose monitoring system with embedded sensors according to claim 5, characterized in that, The armor abrasion-resistant layer is formed by integral extrusion coating. The monitoring system also includes an outer sheath layer, which is placed outside the outermost armored abrasion layer.

7. The marine mining hose monitoring system with embedded sensors according to claim 1, characterized in that, The inner lining layer includes a wear-resistant layer and an outer material layer arranged from the inside out; And / or, the monitoring system also includes a signal transmission cable connected to an acoustic sensor, the signal transmission cable being wound around the outside of the inner lining.

8. The marine mining hose monitoring system with embedded sensors according to claim 3, characterized in that, The inner side of the base and the inner side of the polymer sheath are on the same side, and the outer side of the base and the outer side of the polymer sheath are on the same side.

9. A method for manufacturing a marine mining hose monitoring system with embedded sensors, characterized in that, The marine mining hose monitoring system with embedded sensing as described in claim 3 includes: the base and the polymer sheath layer are embedded and extruded on the outside of the inner liner layer in the same layer, so that the inner side of the base and the inner side of the polymer sheath layer are extruded and connected on the same surface, and the outer side of the base and the outer side of the polymer sheath layer are extruded and connected on the same surface.

10. A method for monitoring marine mining hoses with embedded sensors, characterized in that, The marine mining hose monitoring system using any one of claims 1 to 8 includes: embedding an acoustic sensor in the base, installing the base on the outside of the inner lining, and monitoring the flow of the medium fluid in the inner lining and the operating status of the pipeline itself through the acoustic sensor.

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