Multi-Ply Cryogenic Conduit Assembly for Leak-Monitored Compliance
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Solution Overview
Problem
Flexible conduits in cryogenic propulsion systems are susceptible to manufacturing variances and incidental damage, which can lead to potential failure of pressurized-propellant feed lines, posing a risk to the main propulsion system if not timely identified.
Innovation Solution
A conduit design featuring a bellows structure with corrugated plies and a sensor system to monitor conditions within an interstitial space, allowing for detection of leaks and accommodating displacements, while maintaining hermetic seals through strategically placed welds and allowing for efficient assembly and stress reduction during formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a flexible conduit with bellows structure is used to accommodate displacements, then the adaptability and compliance of the conduit is improved, but the reliability deteriorates due to susceptibility to manufacturing variances and incidental damage
Solution Approach 1:
The bellows is constructed from multiple corrugated plies (first corrugated outboard ply, corrugated inboard ply, second corrugated outboard ply) arranged in layers and hermetically coupled to collars, creating a segmented structure where each ply contributes to overall compliance while the hermetic seals provide redundant containment paths, thereby maintaining reliability through distributed architecture
Solution Approach 2:
A sensor system is integrated to monitor the interstitial space between the first and second collars for detectants indicative of leaks or damage. This feedback mechanism enables real-time detection of compliance structure degradation, allowing for timely intervention before failure occurs, thus resolving the reliability concern while maintaining adaptability
2Reliability
If multiple hermetic welds are implemented to seal the bellows structure, then the reliability and leak prevention is improved, but the device complexity increases
Solution Approach 1:
The first and second collars are hermetically welded to the corrugated plies before final assembly, establishing sealed containment paths in advance. This preliminary hermetic sealing ensures that the interstitial space is isolated from the external environment before the conduit is put into service, guaranteeing reliability while allowing for systematic welding procedures
Solution Approach 2:
The multi-ply bellows structure is nested with the first and second collars hermetically coupled to the outer surfaces of the corrugated plies, creating a nested configuration where the collars contain the interstitial space. This nesting approach consolidates multiple sealing functions into an integrated structure, managing complexity through hierarchical organization
3Ease of manufacture
If the second corrugated outboard ply is not hermetically coupled to the collars, then the ease of manufacture and stress reduction during formation is improved, but the reliability deteriorates due to potential leak paths
Solution Approach 1:
The second corrugated outboard ply serves as an intermediary reinforcement layer positioned within the interstitial space but not hermetically coupled to the collars. This intermediate ply provides structural support and stress distribution during manufacturing and operation, while the hermetic sealing function is separately provided by the first and second collars coupled to the inner and outer plies, maintaining reliability without compromising ease of manufacture
Solution Approach 2:
Different hermetic coupling configurations are applied to different plies: the first corrugated outboard ply and corrugated inboard ply are hermetically coupled to the collars to provide primary sealing, while the second corrugated outboard ply is left uncoupled to provide local reinforcement without compromising the overall hermetic seal. This differentiated approach optimizes both manufacturability and reliability
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 conduit provides a compliant structure for cryogenic fluids, enabling reliable and efficient fluid transport by detecting leaks and reducing stress on the bellows, thus preventing damage and ensuring the integrity of the propulsion system.
Implementation Method 1
a first weld, hermetically coupling the first outer collar portion and the first inner collar portion
Implementation Method 2
The first sensor, being communicatively coupled with the interstitial space, allows the first sensor to monitor conditions within the interstitial space. In particular, the first sensor enables detection of leaks in the corrugated inboard ply by detecting changes in conditions within the interstitial space.
Implementation Method 3
the second corrugated outboard ply, being unconstrained relative to the first inner collar portion and the second inner collar portion, helps reduce stress on the plies of the bellows, during formation of the corrugations of the bellows
Implementation Method 4
The conduit provides a compliant structure for transportation of fluids, such as cryogenic fuels, that accommodates displacements encountered during operation
Data Source
AI summary
A method of fabricating a conduit comprises steps of attaching a first tubular outboard ply to a first inner collar portion of a first collar with a third weld and attaching the first tubular outboard ply to a second inner collar portion of a second collar with a fifth weld. The method also comprises steps of interconnecting the first inner collar portion and a first outer collar portion of the first collar with a first weld, interconnecting the second inner collar portion and a second outer collar portion of the second collar with a sixth weld, attaching a trimmed first corrugated-inboard-ply end of a corrugated inboard ply to the first outer collar portion with a second weld, attaching a trimmed second corrugated-inboard-ply end of a corrugated inboard ply to the second outer collar portion with a fourth weld, and communicatively coupling a first sensor with an interstitial space.