Composite High-Pressure Vessel Fabrication With Embedded Optical Fiber Sensing
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Solution Overview
Problem
Existing pressure vessel monitoring systems fail to accurately monitor internal stresses and temperatures under dynamically changing conditions, leading to potential structural failures due to undetected early signs of damage.
Innovation Solution
Integrate optical fibers within the composite reinforcing layer of the pressure vessel, guiding them along the generatrice of the casing with large bending radii and employing different winding patterns to minimize signal loss and measurement errors, enabling separate measurement of axial and radial deformations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If optical fibers are integrated within the composite reinforcing layer for monitoring internal stresses and temperatures, then measurement precision and reliability are improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The optical fiber is integrated directly into the composite reinforcing layer during the winding process, merging the monitoring function with the structural reinforcement function. The fiber is embedded within the resin-impregnated filament bundles, creating a unified structure that serves both mechanical support and stress/temperature sensing purposes.
Solution Approach 2:
The composite reinforcing layer serves dual functions: providing structural strength to withstand high pressure and containing the optical fiber for monitoring internal stresses and temperatures. This multi-functional design eliminates the need for separate monitoring systems and reduces overall device complexity.
2Measurement precision
If optical fibers are guided along the generatrice with large bending radii, then signal loss is reduced and measurement accuracy is improved, but the winding process complexity increases
Solution Approach 1:
The optical fiber is routed along the generatrice of the cylindrical casing with controlled large bending radii, avoiding sharp angles and tight curves. This curved path design minimizes optical signal loss while maintaining measurement accuracy, and the winding head is configured to automatically follow this curved trajectory during the reinforcing layer application.
Solution Approach 2:
The winding parameters (speed, tension, path radius) are specifically adjusted to ensure the optical fiber is laid down with adequate bending radius. The system dynamically controls these parameters during the winding process to maintain optimal fiber geometry for signal transmission while completing the reinforcing layer application.
3Reliability
If different winding patterns are employed to minimize signal loss, then measurement reliability is improved, but manufacturing time and process complexity increase
Solution Approach 1:
The reinforcing layer is applied in multiple sequential passes with different winding patterns (e.g., longitudinal, helical, transverse). The optical fiber is integrated into each pass, and the segmented approach allows optimization of fiber routing in each layer to minimize signal loss while maintaining overall manufacturing efficiency through automated winding heads.
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
Enhances the accuracy and sensitivity of stress and temperature monitoring, allowing early detection of subtle damage, thereby preventing structural failures and increasing safety by integrating the monitoring system directly with the tank structure.
Implementation Method 1
at least one optical fiber (6) is embedded in at least one layer of the supporting braid (2), wherein its ends are led outside the composite reinforcing coating. At least one optical fiber (6) is led in a polar braid, with an angle of inclination α to the tank axis of 0°-30°.
Implementation Method 2
Integrate optical fibers within the composite reinforcing layer of the pressure vessel, guiding them along the generatrice of the casing with large bending radii
Data Source
AI summary
A composite high-pressure vessel comprises a casing (1) made by blow molding a preform made of a thermoplastic material, a connection stub (3), a bottom dome (4) and a composite reinforcing coating made of a supporting braid (2) that consists of a bundle of filaments (5) embedded in resin, preferably containing nano-additives. At least one optical fiber (6) is embedded in at least one layer of the supporting braid (2), and its ends are led outside the composite reinforcing coating. The optical fiber (6) is led in a polar braid between the connection stub (3) and the bottom dome (4), at an angle of inclination to the vessel axis of 0°-30°. The optical fiber (6) may be additionally led in a hoop braid, with an angle a of inclination to the vessel axis of 45°-90°.