Corrosion Detection Sensor Array Segmentation
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Solution Overview
Problem
Current corrosion monitoring methods are inadequate for reliably measuring uniform and localized corrosion rates, as they are prone to noise, complex, and costly, and fail to provide unambiguous results, especially for localized corrosion which is a leading cause of system failure.
Innovation Solution
A corrosion monitoring device with conductive sensor elements and a separator element, which changes impedance when exposed to a corrosive environment, providing binary signals indicating whether corrosion has penetrated through a predetermined thickness, allowing for robust and cost-effective monitoring of localized corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If LPR technique is used to measure corrosion rate, then uniform corrosion can be detected, but localized corrosion cannot be reliably measured and the measurements are susceptible to noise
Solution Approach 1:
The sensor is divided into multiple discrete conductive sensor elements arranged in an array, where each element independently monitors corrosion at its specific location. This segmentation allows the system to detect localized corrosion events at individual elements while maintaining overall monitoring coverage, resolving the contradiction between precise measurement and reliability for localized corrosion.
Solution Approach 2:
An intermediary evaluation circuit is introduced between the sensor elements and the reading device. This circuit processes the signals from multiple sensor elements, filtering noise and identifying localized corrosion events by analyzing patterns across the sensor array, thereby improving measurement reliability without sacrificing precision.
2Measurement precision
If ER-type sensors are used to measure corrosion, then corrosion rate can be determined, but the sensor bulk is considerable due to long exposed strip length
Solution Approach 1:
The sensor elements are designed as small, discrete conductive elements rather than a continuous long strip. Each element is optimized for its specific monitoring function, allowing precise corrosion measurement while minimizing the overall sensor volume. The localized nature of each element enables compact arrangement while maintaining measurement capability.
3Volume of moving object
If sensor thickness is reduced to minimize bulk, then sensor size decreases, but sensor life is reduced due to faster complete corrosion
Solution Approach 1:
The system dynamically manages sensor elements by monitoring their individual corrosion states. When a sensor element is consumed, it can be replaced or the system can switch to other elements, extending the overall monitoring duration. This dynamic approach allows use of thinner, smaller elements while maintaining extended operational life through element replacement strategies.
4Duration of action of stationary object
If multiple sensor elements of varying thicknesses are used, then sensor life is extended and cumulative measurements are provided, but device complexity increases
Solution Approach 1:
Multiple sensor elements of varying thicknesses are merged into a single integrated sensor array that functions as one cohesive monitoring unit. The evaluation circuit processes all elements uniformly, treating them as a single data stream, which extends sensor life through cumulative measurements while minimizing the increase in device complexity by avoiding separate processing paths for each element type.
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
The device effectively measures localized corrosion with reduced noise susceptibility and cost, providing cumulative measurements and extending sensor life by using multiple sensor elements of varying thicknesses, enabling accurate prediction of corrosion propagation through given thicknesses.
Implementation Method 1
When the separator element remains dry, a virtual open circuit (high impedance) is provided between the sensor and backing elements, thereby inhibiting the flow of current through the device
Implementation Method 2
the separator element becomes conductive due to wetting from exposure to the processing fluid, thus providing a virtual closed circuit and allowing current to flow through the device
Implementation Method 3
Over time, a gradual loss of material occurs across the thickness of the sensor element due to the corrosive action of the processing fluid. Once the corrosion has penetrated through the predetermined thickness of the sensor element, the impedance between the sensor and backing elements is reduced
Data Source
AI summary
A corrosion monitoring device for monitoring corrosion in fluid containing systems and other equipment exposed to a corrosive environment comprising sensor elements having a composition substantially the same as the equipment being monitored, the sensor elements having a predetermined thickness for exposure to a corrosive solution of the fluid containing system. An electrical property of the monitoring device changes when corrosion penetrates through the thickness of the sensor element. A digital output device generates a first binary signal when corrosion has not penetrated through the thickness of the sensor elements, and a second binary signal when corrosion has penetrated through the thickness of the sensor elements. Multiple sensor elements may be used to provide multiple binary signals. Information from the digital outputs may be processed to provide a cumulative log of corrosion measurements.