Diagnostic methods
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Solution Overview
Problem
Conventional fluid systems lack proactive health verification, leading to unplanned shutdowns and economic impacts, especially when serving multiple customers, as they do not have self-testing capabilities to detect anomalies timely.
Innovation Solution
A diagnostic method that includes a bypass conductor, valve, pump, pressure sensor, and flow sensor to monitor fluid flow and pressure, allowing for real-time identification of malfunctions and alerts to service personnel, enabling the system to continue operating with alternative components until repairs can be made.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fluid systems operate without active health verification, then the system structure remains simple and operational continuity is maintained, but anomalies are detected too late causing unplanned shutdowns and economic losses
Solution Approach 1:
The patent implements preliminary diagnostic actions by continuously monitoring system parameters (pressure, flow rate, temperature) before failures occur. The diagnostic method performs self-tests during normal operation and at scheduled intervals, detecting anomalies early enough to plan maintenance during off-peak hours, thus preventing unplanned shutdowns while maintaining acceptable system complexity through automated monitoring.
Solution Approach 2:
The patent establishes feedback loops where sensor data from pressure sensors, flow sensors, and temperature sensors is continuously analyzed against baseline parameters. When deviations exceed thresholds, the system generates alerts and performs adaptive self-tests, creating a closed-loop diagnostic system that improves reliability through real-time monitoring without requiring complex manual intervention systems.
2Measurement precision
If the system performs comprehensive self-tests during operation, then anomaly detection capability is improved, but system downtime and operational interruptions increase
Solution Approach 1:
The patent implements periodic self-testing where comprehensive diagnostics are performed at scheduled intervals (e.g., daily, weekly, or monthly) rather than continuously. During these periodic tests, the system temporarily suspends operation to perform thorough measurements of pressure drops, flow rates, and temperature differentials across components. This approach achieves high measurement precision for anomaly detection while minimizing downtime by concentrating tests to specific maintenance windows.
Solution Approach 2:
The patent employs adaptive diagnostic strategies where the extent of self-testing is adjusted based on system conditions and risk assessments. For critical components showing early signs of degradation, more frequent and thorough tests are performed. For stable components, testing is reduced or skipped, allowing the system to maintain high detection precision for problematic areas while minimizing unnecessary downtime in stable areas.
3Difficulty of detecting and measuring
If the system implements real-time monitoring with multiple sensors, then the ability to detect and locate malfunctions is improved, but the cost and complexity of the system increases
Solution Approach 1:
The patent divides the fluid heating system into discrete functional segments (heat exchanger, pump, valves, conduits) and places sensors at strategic boundaries between segments. Pressure sensors measure differential pressure across heat exchangers, flow sensors monitor specific circuit segments, and temperature sensors are positioned at inlet/outlet points. This segmentation approach enables precise malfunction localization to specific components or segments while keeping the overall sensor network manageable by focusing measurements where they provide maximum diagnostic value.
4Productivity
If the system continues operating with alternative control strategies during anomalies, then service continuity is maintained, but the risk of further system damage increases
Solution Approach 1:
The patent implements compensatory control strategies that are pre-programmed to activate when specific anomalies are detected. For example, when a heat exchanger shows reduced efficiency, the system automatically adjusts pump speed, valve positions, or extends circulation time to compensate for the degradation. When a sensor fails, redundant sensors or alternative measurement methods are activated. These beforehand cushioning measures maintain service continuity by compensating for component failures while including safety thresholds that prevent operation under conditions that would cause catastrophic damage.
Data Source
AI summary
A diagnostic method for verifying the proper functioning of flow devices of a fluid system including at least one of at least one fluid heater, a bypass conductor connected in parallel to the at least one fluid heater, a bypass valve configured to control flow through the bypass conductor, at least one flow valve for controlling a fluid flow through the fluid system, at least one pump, at least one pressure sensor for obtaining a pressure of the fluid flow and at least one flow sensor for obtaining a flowrate of the fluid flow. The method includes selectively turning on and off the bypass valve and the at least one pump and obtaining pressure measurements at various times during the execution of the diagnostic method to identify the health of the at least one pressure sensor and the at least one pump.