Embedded Sensors in Additive Subsea Nodes
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Solution Overview
Problem
Existing methods for measuring and estimating fatigue damage in offshore structures, particularly at nodal intersections of tubular members, are prone to error due to the difficulty in accessing underwater locations and the complexity of dynamic motions and stresses caused by Metocean conditions, leading to inaccurate predictive analyses for structures subjected to vibration-induced fatigue.
Innovation Solution
The integration of sensors, such as accelerometers, strain gauges, and thermocouples, within additively manufactured subsea connection nodes, allowing for real-time monitoring of stresses and vibrations at critical locations that are inaccessible with traditional sensors, and utilizing advanced analysis to determine optimal sensor placement for accurate data collection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional sensors are used to monitor fatigue damage at underwater nodal intersections, then the monitoring capability is established, but the measurement precision and reliability are compromised due to inaccessible locations and complex dynamic conditions
Solution Approach 1:
Sensors are embedded within the nodal intersection structure during the manufacturing process, before the structure is deployed to underwater locations. This preliminary placement ensures that sensors are positioned at optimal locations for measuring fatigue damage and dynamic motions, eliminating the need for difficult post-deployment sensor installation and ensuring measurement precision from the outset.
Solution Approach 2:
Sensors are nested within encapsulating structures that are integrated into the nodal intersection body. This nesting approach protects the sensors from the harsh underwater environment while maintaining their ability to accurately measure stresses and vibrations at the critical nodal locations, thereby improving measurement precision without increasing deployment difficulty.
2Reliability
If multiple sensors are deployed at inaccessible underwater locations to monitor structural health, then monitoring coverage is improved, but the device complexity and installation difficulty increase
Solution Approach 1:
Multiple sensors are merged into a single integrated monitoring system embedded within the nodal intersection structure. The sensors are combined with encapsulating structures and mounting features that are all integrated into one unified component, allowing comprehensive monitoring of structural health without requiring multiple separate deployment operations or complex installation procedures.
Solution Approach 2:
The entire sensor assembly, including multiple sensors and their encapsulating structures, is prepared and integrated into the nodal intersection during manufacturing. This preliminary action consolidates what would otherwise be multiple complex deployment operations into a single simplified process, improving reliability while reducing device complexity and installation difficulty.
3Measurement precision
If predictive models are developed using complex parameter combinations for Metocean conditions, then the accuracy of fatigue damage estimation is improved, but the computational complexity and time required for analysis increase
Solution Approach 1:
The embedded sensors provide real-time feedback data on actual stresses, vibrations, and dynamic motions at the nodal intersection. This feedback enables the development of predictive models that are calibrated using actual measurements rather than relying solely on complex parameter combinations and theoretical models, thereby improving accuracy while reducing computational complexity through data-driven approaches.
Solution Approach 2:
The patent replaces complex mechanical and computational modeling approaches with direct sensor-based measurement and data analysis. By using embedded sensors to directly measure stresses and vibrations, the need for complex predictive models based on parameterized Metocean conditions is reduced, improving accuracy while simplifying the analytical approach through direct observation rather than indirect modeling.
4Ease of operation
If sensors are embedded within additively manufactured nodal intersections, then access to critical measurement locations is achieved, but the manufacturing process complexity increases
Solution Approach 1:
The additively manufactured nodal intersection incorporates local quality features such as encapsulating structures and sensor mounting features that are integrated specifically at locations where sensors need to be embedded. This localized approach to manufacturing complexity allows access to critical measurement locations while keeping the overall manufacturing process manageable by applying advanced manufacturing techniques only where necessary.
Solution Approach 2:
The manufacturing process utilizes additive manufacturing technology with controlled parameters to create complex geometries that enable sensor embedding. By changing the manufacturing approach from traditional subtractive or assembly-based methods to additive manufacturing with specific parameter control, the patent achieves access to critical measurement locations while managing manufacturing complexity through process optimization rather than inherent complexity.
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
This approach enables precise monitoring of structural health and fatigue resistance by embedding sensors within the nodes, reducing the need for extensive sensor placement and improving the accuracy of predictive models for offshore structures, especially under complex vibration conditions like vortex-induced vibrations.
Implementation Method 1
The at least one sensor may be an accelerometer, a strain gauge, a thermocouple, a rate sensor, a piezo electric sensor, and/or an optical sensor.
Implementation Method 2
The at least one sensor may be an accelerometer, a strain gauge, a thermocouple, a rate sensor, a piezo electric sensor, and/or an optical sensor.
Implementation Method 3
The at least one sensor may be an accelerometer, a strain gauge, a thermocouple, a rate sensor, a piezo electric sensor, and/or an optical sensor.
Implementation Method 4
The at least one sensor may be an accelerometer, a strain gauge, a thermocouple, a rate sensor, a piezo electric sensor, and/or an optical sensor.
Data Source
AI summary
A method and apparatus for forming a sensor within a subsea node using additive manufacturing.