Dry-Side Sensor Layer for Predictive Diaphragm Valve Monitoring
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Solution Overview
Problem
Existing membrane valves with integrated sensors require replacement along with the membrane, leading to increased costs and inefficiencies, as they lack predictive maintenance capabilities and decoupling of membrane function and condition monitoring.
Innovation Solution
A sensor layer comprising pressure sensors arranged on the dry side of the membrane valve, allowing for predictive maintenance by detecting force changes, sealing issues, and membrane condition, which can be retrofitted onto existing valves, enabling early detection of damage and optimizing membrane replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensors are integrated inside the diaphragm, then condition monitoring is enabled, but the sensor must be replaced together with the diaphragm, increasing costs and reducing efficiency
Solution Approach 1:
The sensor system is segmented into two independent parts: the disposable diaphragm and the reusable sensor housing. This allows the sensor to be separated from the diaphragm, enabling the sensor to remain functional while the diaphragm is replaced, thus improving replacement efficiency and reducing costs.
Solution Approach 2:
The sensor is extracted from the diaphragm structure and placed in a separate reusable housing on the dry side. This extraction allows the sensor to be decoupled from the diaphragm's lifecycle, enabling continuous sensor operation while the diaphragm is replaced, resolving the contradiction between monitoring capability and replacement efficiency.
2Reliability
If sensors are integrated inside the diaphragm, then early damage detection is enabled, but tooling costs increase and scalability is reduced
Solution Approach 1:
The sensor is extracted from the diaphragm and placed in a separate reusable housing. This separation allows the sensor to be manufactured independently using standard components, reducing tooling costs and enabling scalable production without requiring expensive integrated sensor-diaphragm manufacturing processes.
Solution Approach 2:
The reusable sensor housing can be applied to multiple diaphragms and valve types, making the sensor system universal. This multi-functionality reduces per-unit tooling costs and enables scalable deployment across different applications while maintaining damage detection capability.
3Reliability
If critical components are integrated into the membrane, then monitoring capability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The monitoring system is segmented into a simple reusable sensor housing containing standard pressure sensors, separated from the diaphragm. This segmentation eliminates the need to integrate complex components into the membrane during manufacturing, reducing assembly complexity while maintaining monitoring capability through the external sensor arrangement.
4Adaptability or versatility
If sensors are placed on the dry side of the diaphragm, then retrofittability is enabled and membrane function is decoupled from monitoring, but sensor integration complexity increases
Solution Approach 1:
The sensor is extracted and positioned on the dry side of the diaphragm in a separate housing. This extraction enables retrofittability to existing valves while the modular housing design with standardized pressure sensors actually reduces integration complexity compared to custom integrated solutions, as the sensor can be independently installed and configured.
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 sensor layer reduces tooling costs, allows for scalable sensor use, and provides predictive maintenance, enabling timely membrane replacement, improved assembly processes, and continuous condition monitoring, thus enhancing operational efficiency and reducing downtime.
Implementation Method 1
The sensor array comprises a plurality of pressure sensors, each designed to generate a signal that characterizes a force acting perpendicular to the respective section of the sensor array
Data Source
Figure 1a
Figure 1b
Figure 2
AI summary
A sensor layer (100) is provided for arrangement on a dry side (202) of a diaphragm (200) of a diaphragm valve (300). The sensor layer (100) comprises a plurality of pressure sensors (420a-d; 430a-d; 440a-b; 450; 490a-b) which are configured to generate a respective signal (s420a-d; s430a-d; s440a-b; s450; s90a-b) which characterizes a force acting, in particular, perpendicular to the respective associated section (20a-d; 30a-d; 40a-b; 50; 40c-d) of the sensor layer (100).