Embedded Sensor System in Metal Tube Cavity
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Solution Overview
Problem
Metal tubes in various applications face challenges due to wear and aging, leading to pipe bursts, and existing sensor and signal line solutions have short durability when exposed to environmental influences or placed inside tubes, making it difficult to monitor their state effectively, especially in long tubes over 50 meters.
Innovation Solution
A system comprising a signal line and sensor placed within a cavity formed by a metal strip or plate, where the signal line and sensor are protected between two concentric metal tubes, allowing for the transmission of data along the tube's length without exposure to excessive wear or environmental influences, and multiple sensors are spaced along the length to monitor parameters like temperature, pressure, and movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If sensors and signal lines are placed on the outside of the tube, then they are easily accessible for installation and maintenance, but their durability is short due to environmental influences
Solution Approach 1:
The patent embeds the signal line and sensors inside the tube cavity, nesting them within the protected interior space. This nesting approach shields the sensitive components from external environmental factors like moisture, temperature extremes, and mechanical damage, thereby improving durability while maintaining monitoring functionality throughout the tube length
2Reliability
If sensors and signal lines are placed inside the tube cavity, then they are protected from environmental influences, but installation becomes difficult especially for long tubes
Solution Approach 1:
The signal line and sensors are pre-assembled into a integrated unit before tube fabrication. The tube is then formed around this pre-assembled monitoring system, eliminating the need to install sensitive components inside the tube after it is already in place. This preliminary assembly approach makes installation feasible even for very long tubes where post-fabrication access would be impractical
3Productivity
If fluid is transferred through the tube cavity, then the tube serves its primary transport function, but any sensor placed in the cavity has shortened durability
Solution Approach 1:
The tube wall acts as an intermediary barrier between the fluid and the sensors. The signal line and sensors are positioned inside the cavity but remain separated from direct fluid contact by the tube material, allowing fluid transport to continue uninterrupted while the tube wall protects the sensors from degradation caused by fluid exposure
Data Source
Figure 1~2
Figure 3
AI summary
The signal transmission system or a sensor system (1, 1') comprises at least one signal line (2) and at least once sensor (10) connected to the signal line, a first tube (3) formed of a metal strip or metal plate (4) having two longitudinal edges (5) extending in a longitudinal direction and two transverse edges connecting the longitudinal edges, wherein the metal strip or metal plate (4) is formed to a cavity by joining the longitudinal edges of the metal strip or metal plate together, and wherein the at least one signal line (2) is located in the cavity. The present disclosure further relates to a method for manufacturing such a signal transmission system or a sensor system.