Compact Leak Detection for Large Volume Units
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Solution Overview
Problem
Conventional leak detection systems are inefficient for large volume products due to the need for excessively large precision constant pressure vessels, which are costly, space-intensive, and not portable, making it difficult to test large units without damaging them and ensuring product integrity during shipping and storage.
Innovation Solution
A system comprising a compact accumulator, a flow controller, a micro-flow sensor, and a pressure controller that maintains constant pressure, allowing for precise leak detection in large volume units using a portable unit with a quick fill valve and pressure sensor to minimize equipment size and ensure accurate testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a conventional precision constant pressure vessel is used for leak detection, then measurement precision is improved, but volume of stationary object increases significantly
Solution Approach 1:
The patent changes the operating parameters by using a much smaller accumulator (less than 0.5 m³ compared to conventional 10x larger vessels) while maintaining measurement precision through electronic flow control and compensation mechanisms. The flow controller dynamically adjusts gas flow to compensate for the smaller accumulator size, maintaining stable pressure conditions necessary for precise leak detection.
Solution Approach 2:
The patent replaces the purely mechanical conventional pressure vessel system with an integrated electronic control system. The flow controller and pressure sensor work together to electronically regulate and maintain constant pressure in the accumulator, substituting mechanical size with electronic control intelligence to achieve the same measurement precision.
2Measurement precision
If a conventional precision constant pressure vessel is used for leak detection, then measurement precision is improved, but area of stationary object increases
Solution Approach 1:
The patent reduces the physical footprint by changing the accumulator volume parameter to less than 0.5 m³, which is dramatically smaller than conventional systems. This size reduction is compensated by enhancing the control system parameters, using electronic flow controllers and sensors to maintain the precision required for micro-meter scale leak detection.
Solution Approach 2:
The patent integrates multiple functional components into a compact nested arrangement. The flow controller, pressure sensor, and accumulator are integrated into a single portable unit with compact architecture, where components are nested or closely arranged to minimize overall equipment footprint while maintaining full functionality for precise leak detection.
3Measurement precision
If a conventional precision constant pressure vessel is used for leak detection, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent merges the accumulator, flow controller, pressure sensor, and related components into a single integrated portable unit. This consolidation combines multiple functions into one device, reducing the overall system complexity compared to conventional separate systems while maintaining measurement precision through the coordinated operation of integrated components.
Solution Approach 2:
The portable unit is designed with multi-functionality, serving as both the pressure source and the measurement system. The integrated unit can perform leak detection on various UUTs of different sizes, and the system adapts to different testing requirements, reducing the need for multiple specialized devices and thereby simplifying the overall equipment portfolio.
4Measurement precision
If a conventional precision constant pressure vessel is used for leak detection, then measurement precision is improved, but productivity decreases due to longer testing time
Solution Approach 1:
The system performs preliminary quick filling of the UUT using the quick fill valve before the actual leak detection measurement. This preliminary action rapidly establishes the initial pressure condition, allowing the subsequent precise measurement phase to begin sooner and reducing the total testing time while maintaining measurement accuracy.
Solution Approach 2:
The patent employs dynamic flow control to adapt the gas supply rate to the specific needs of each testing phase. The flow controller dynamically adjusts flow rates during quick filling versus during precise measurement, optimizing the process speed for each phase while maintaining the precision required for accurate leak detection throughout.
5Measurement precision
If a conventional precision constant pressure vessel is used for leak detection, then measurement precision is improved, but portability is lost
Solution Approach 1:
The patent fundamentally changes the size parameter of the pressure source by using an accumulator less than 0.5 m³, which enables the entire system to be transported as a portable unit. This size reduction is compensated by electronic control mechanisms that maintain the precision required for micro-meter scale leak detection, achieving both portability and measurement accuracy.
Solution Approach 2:
The patent integrates all necessary components (accumulator, flow controller, pressure sensor, valves) into a single nested portable unit architecture. This compact nested design allows the entire leak detection system to be transported to customer sites or end-user locations, enabling on-site verification of product integrity without requiring large fixed infrastructure.
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
Enables efficient and precise leak detection in large volume products, reducing equipment size and cost while allowing for testing at the point-of-use, ensuring product integrity and reducing testing time.
Implementation Method 1
a flow sensor configured to supply gas from the accumulator to a UUT, to measure a flow rate of the supplied gas
Implementation Method 2
the flow controller responds to the measured flow rate by supplying flow compensation gas to the accumulator to maintain a desired pressure in the accumulator
Implementation Method 3
a pressure sensor configured to measure a pressure of gas in the UUT; wherein the pressure controller cooperates with the quick fill valve to fill the UUT with gas in response to a measurement of pressure of gas in the UUT from the pressure sensor
Data Source
AI summary
A system for detecting leaks is provided comprising an accumulator, a flow controller in communication with the accumulator, and a flow meter/sensor in communication with the accumulator, the flow controller and a UUT. The flow meter is structured to supply gas from the accumulator to the UUT and measure a flow rate of the supplied gas, the flow meter providing feedback to the flow controller representing the flow rate, and the flow controller responding to the feedback by supplying flow compensation gas to the accumulator to maintain a desired pressure in the accumulator. Methods are also provided for detecting small leaks, especially with large units under test (“UUTs”).