Elastomeric Expansion Joint Pre-Failure Sensor
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Solution Overview
Problem
Elastomeric expansion joints in piping systems weaken and fail over time, leading to premature replacement when detected solely by time-in-service measurements, resulting in unnecessary costs and downtime.
Innovation Solution
Integration of a stretchable sensor with electrodes and an analysis circuit within or attached to the elastomeric body, which detects changes in electrical characteristics due to stretching or contraction, emitting an alarm signal when predetermined failure conditions are met, such as excessive expansion or stiffening, allowing for timely and non-premature replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If replacement is based on time-in-service measurement, then the joint is replaced before failure, but the joint may be replaced prematurely causing unnecessary cost and downtime
Solution Approach 1:
The sensor provides preliminary detection of failure conditions by monitoring physical changes in the elastomeric material (swelling, stiffening, weakening) before actual failure occurs. This allows replacement to be scheduled at the optimal time - sufficiently early to prevent failure but not so early as to be premature, thereby reducing unnecessary downtime while maintaining reliability
Solution Approach 2:
The sensor provides continuous feedback on the actual condition of the expansion joint by measuring physical properties of the elastomeric material. This feedback replaces time-based scheduled maintenance with condition-based maintenance, allowing the system to adapt replacement timing to the actual state of the joint, thus avoiding both premature and late replacement
2Reliability
If replacement is based on time-in-service measurement, then the joint is replaced before failure, but unnecessary replacement cost is incurred
Solution Approach 1:
The sensor provides preliminary detection of actual failure conditions (material swelling, stiffening, weakening) before catastrophic failure. This enables replacement to be timed optimally - early enough to prevent failure but not prematurely - thereby eliminating unnecessary replacement costs while maintaining reliability
Solution Approach 2:
The sensor provides continuous feedback on the actual physical condition of the elastomeric material, enabling condition-based maintenance decisions. This feedback mechanism replaces cost-inefficient time-based replacement with economically optimal condition-based replacement, reducing unnecessary expenditure while ensuring 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
Enables the detection of approaching failure conditions in elastomeric expansion joints, allowing for routine replacement before actual failure, thereby reducing costs and downtime by providing timely alerts based on material weakening or stiffening.
Implementation Method 1
The sensor element has two spaced apart electrodes and an intervening element, the element configured to provide a varying electrical characteristic when the sensor stretches or contracts and an electrical potential is applied to the electrodes
Data Source
AI summary
An expansion joint including a hollow elastomeric body having coupling flanges at each open end configured to connect to flanges of a pipe system. The hollow elastomeric body is made of a material including an elastomer and fibers. A stretchable sensor is located within the material of the hollow elastomeric body. The sensor is configured to provide a varying electrical characteristic when the sensor is stretched or contracts. An analysis circuit is connected to the sensor, the analysis circuit configured to receive the varying electrical characteristic and to emit a signal corresponding to a level of the electrical characteristic received by the analysis circuit.