Cellular Ultrasonic Sensor Interface for Pipe Integrity Monitoring
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Solution Overview
Problem
Current wireless mesh network systems for ultrasonic monitoring of pipe integrity are costly to deploy and require IT infrastructure, limiting their accessibility and practicality for frequent, high-resolution measurements due to high initial capital expenses and complex installation processes.
Innovation Solution
A battery-powered, cellular-enabled ultrasonic digital sensor interface (DSI) system that connects ultrasonic sensors to a cellular network, allowing for low-cost deployment and operation independent of plant IT infrastructure, with data transmitted to a cloud server for storage and analysis, enabling a subscription-based business model.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If wireless mesh network systems are used for ultrasonic monitoring, then data transmission capability is improved, but deployment cost and complexity increase significantly
Solution Approach 1:
The patent extracts the data transmission function from the complex mesh network infrastructure and implements it through simple cellular-enabled devices. Each ultrasonic sensor unit independently connects to cellular networks, eliminating the need for complex mesh network gateway installations and IT infrastructure integration, thereby significantly reducing deployment complexity while maintaining data transmission capability.
Solution Approach 2:
The patent introduces cellular networks as an intermediary communication channel between the ultrasonic sensor units and the data collection system. This intermediary approach replaces the direct but complex mesh network infrastructure with a simpler cellular-based communication pathway, reducing deployment complexity while ensuring reliable data transmission.
2Loss of information
If mesh network gateways are deployed for ultrasonic monitoring, then data transmission capability is improved, but initial capital expenses increase
Solution Approach 1:
The patent replaces expensive, complex mesh network gateways with affordable cellular-enabled sensor units. Each sensor unit independently connects to cellular networks, eliminating the need for costly gateway installations. The system uses standard cellular technology and inexpensive components to achieve data transmission, significantly reducing initial capital expenses while maintaining functional capability.
Solution Approach 2:
The patent extracts the data transmission function from the expensive mesh network gateway infrastructure and implements it through individual cellular connections at each sensor unit. This extraction eliminates the need for costly gateway hardware and installation, reducing initial capital expenses while preserving data transmission capability.
3Ease of operation
If manual probe positioning is used for ultrasonic measurements, then measurement simplicity is maintained, but measurement precision and data consistency deteriorate
Solution Approach 1:
The patent implements self-service through automated sensor units that automatically position themselves and perform measurements without manual probe positioning. The sensor units are equipped with automatic positioning mechanisms and can independently execute ultrasonic measurements, eliminating operator variability and ensuring consistent, high-precision measurements while maintaining operational simplicity.
Solution Approach 2:
The patent introduces dynamic positioning capabilities to the measurement system, allowing sensor units to automatically adjust their positions and orientations to optimize measurement quality. This dynamic approach replaces static manual positioning with automated adaptive positioning, improving measurement precision while keeping the system easy to operate through automation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Facilitates cost-effective, frequent, and high-resolution ultrasonic monitoring of pipe integrity without the need for expensive gateway installations or IT personnel, reducing deployment complexity and capital expenses, while providing accessible data through a cloud-based interface.
Implementation Method 1
The instrument excites the probe via an electrical pulse, and the probe, in turn, generates an ultrasonic pulse which is transmitted through the structure. The probe also receives an echo of the ultrasonic pulse from the structure
Implementation Method 2
The DSI has a cellular transceiver for transmitting a cellular signal based directly or indirectly on at least the A-scan signal
Data Source
AI summary
An ultrasound sensing system for monitoring the condition or integrity of a structure, comprising: a plurality of ultrasound sensors, each sensor being configured to receive at least one first electrical signal, transmit an ultrasound signal in response to said first electrical signal, receive at least one reflected ultrasound signal, and transmit a second electrical signal in response to said reflected ultrasound signal, said first and second electrical signals being analog; and at least one digital sensor interface (DSI) to which at least a portion of said sensors are connectable, said DSI being configured to transmit said first electrical signal and receive said second electrical signal, and to generate at least an A-scan signal based on said first and second electrical signals for each sensor, said DSI having a cellular transceiver for transmitting a cellular signal based directly or indirectly on at least said A-scan signal, said cellular signal including an address corresponding to said at least one DSI.