Crane-Mounted Sensor Box for Automated Valve Hall Inspection
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Solution Overview
Problem
Current inspection and condition monitoring methods for industrial halls, such as valve halls in HVDC plants, are labor-intensive and often require human intervention, posing risks due to high voltages and electromagnetic interference, and lack the capability for continuous, automated monitoring of large areas.
Innovation Solution
A crane-based inspection and health monitoring system with a movable sensor box that can operate within the industrial hall, utilizing a drive train, crane trolley, crane bridge, and sensor box equipped with various sensors, allowing for three-dimensional scanning and reducing the need for multiple devices, while being easy to install and avoiding interference from electric fields and electromagnetic interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual inspection methods are used, then human intervention is required for monitoring, but labor intensity increases and safety risks arise due to high voltages
Solution Approach 1:
The inspection system extracts the monitoring function from human operators and transfers it to an automated sensor box equipped with multiple sensors (temperature, humidity, pressure, gas detection). The sensor box can be remotely operated via control unit and communication system, eliminating the need for personnel to physically enter the high-voltage valve hall while maintaining continuous monitoring capability.
Solution Approach 2:
The patent introduces an intermediary system consisting of the sensor box, control unit, and communication system that mediates between the inspection objective and the high-voltage environment. This intermediary infrastructure enables automated data collection and transmission without requiring direct human exposure to hazardous conditions.
2Area of stationary object
If multiple inspection devices are deployed to cover large areas, then monitoring coverage increases, but device complexity and installation difficulty increase
Solution Approach 1:
The patent merges multiple inspection functions into a single integrated sensor box that combines temperature sensors, humidity sensors, pressure sensors, gas detection devices, and imaging cameras. This consolidation allows one device to perform what would traditionally require multiple separate inspection systems, reducing overall complexity while maintaining comprehensive monitoring coverage throughout the valve hall.
Solution Approach 2:
The sensor box is designed as a universal inspection platform that can monitor various physical parameters (temperature, humidity, pressure, gas composition) and visual conditions simultaneously. This multi-functional design enables a single device to replace multiple specialized inspection tools, achieving broad area coverage without proportionally increasing system complexity.
3Extent of automation
If inspection equipment is installed inside the valve hall, then monitoring capability improves, but electromagnetic interference from high voltages affects equipment operation
Solution Approach 1:
The sensor box is enclosed in a shielding structure that acts as a protective shell against electromagnetic interference. This shielding allows the sensor box to be positioned within the valve hall close to high-voltage equipment while protecting the electronic sensors and communication systems from electromagnetic disturbances, enabling automated monitoring without signal degradation.
4Measurement precision
If comprehensive sensor suites are used, then inspection quality improves, but installation complexity and cost increase
Solution Approach 1:
The inspection system is segmented into modular components: the sensor box containing various sensors, the control unit for data processing, and the communication system for data transmission. This segmentation allows the system to be installed in stages and enables flexible configuration based on specific inspection requirements, reducing overall installation complexity while maintaining high measurement precision through comprehensive sensor coverage.
Data Source
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AI summary
Inspection and condition monitoring system (1), comprising an industrial hall (100), delimited by at least a wall (101), a ceiling (102) and a floor (103), enclosing a space (104) containing equipment (105). The system (1) furthermore comprises a drive train (11) which is located at a safe position below the ceiling (102) of the industrial hall (100), a crane trolley (12) which is moved by the drive train (11), a crane bridge (13) which supports the crane trolley (12), crane runway rails (14) adapted to support the crane bridge (13), both forming a first rail system (17) such that the crane trolley (12) can move inside the industrial hall (100). The system (1) further comprises at least one sensor box (20).