Flexible Sensor Carrier with Torsional Bracing for Pipeline Inspection
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Solution Overview
Problem
Existing in-line pipe inspection tools with rigid sensor carriers are limited to specific pipeline diameters, and flexible carriers that can adjust curvature are prone to torsional twisting, causing sensor misalignment and ineffective inspection.
Innovation Solution
A flexible sensor carrier with a bracing unit that resists torsional twisting, allowing the carrier to change radius of curvature while maintaining sensor alignment, using a hingedly connected bracing unit that deforms to conform to changes in pipeline diameter without twisting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the sensor carrier is made rigid to maintain sensor alignment, then measurement precision is improved, but adaptability to different pipeline diameters deteriorates
Solution Approach 1:
The sensor carrier is designed as a flexible part-cylindrical body that can dynamically change its radius of curvature to adapt to different pipeline diameters. The carrier includes resiliently flexible elements that allow radial movement while maintaining sensor alignment through the dynamic adjustment of curvature radius, resolving the contradiction between rigidity for alignment and flexibility for adaptability.
Solution Approach 2:
The invention changes the geometric parameter of the sensor carrier by allowing variation in the radius of curvature. The carrier can adjust its curvature radius to match different pipeline diameters, enabling the same sensor array to maintain proper alignment across a range of diameters without requiring physical reconfiguration.
2Adaptability or versatility
If the sensor carrier is made flexible to adapt to different diameters, then adaptability is improved, but structural stability deteriorates due to torsional twisting
Solution Approach 1:
The sensor carrier is segmented into multiple independent flexible elements or segments that can deform individually. This segmentation allows the carrier to accommodate torsional forces and diameter changes without causing cumulative twisting that would misalign the sensors, as each segment can absorb local deformations independently.
Solution Approach 2:
The invention introduces intermediary flexible elements or damping mechanisms between the sensor array and the carrier structure. These intermediaries absorb and isolate torsional forces, preventing them from transmitting to the sensors while still allowing the carrier to flex for diameter adaptation.
3Ease of operation
If the sensor carrier is made flexible to vary radius of curvature, then ease of operation is improved, but manufacturing precision deteriorates due to deformation control
Solution Approach 1:
The sensor positioning system is designed to be dynamic rather than static. The sensors are mounted on adjustable fixtures or flexible mounts that automatically maintain correct positioning as the carrier deforms. This dynamic positioning system compensates for manufacturing tolerances and ensures accurate sensor alignment regardless of the carrier's current curvature state.
Solution Approach 2:
The sensor carrier incorporates self-aligning features such as automatic centering mechanisms or self-adjusting mounting structures. These features allow the sensor array to automatically reposition itself to maintain optimal alignment with the pipeline wall, eliminating the need for high-precision manufacturing of the carrier geometry itself.
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 effective inspection of pipelines with varying diameters by maintaining sensor alignment and conforming to different geometries, ensuring consistent magnetic field detection across a range of diameters.
Implementation Method 1
the sensor carrier is flexible, such that its radius of curvature may vary. Thus, by the flexing of the part-cylindrical body of the sensor carrier, the radius of the cylinder changes
Implementation Method 2
a bracing unit which resists torsional twisting of one part of the sensor carrier relative to another
Implementation Method 3
Sensors are provided between the magnetic poles, which detect the magnetic flux density at the internal surface of the pipe. The magnetic field in the pipe wall is normally constant, but is disturbed by a flux changing feature, such as a defect, weld bead or wall thickness change, and magnetic flux then leaks out of the pipe at such a feature, to be detected by the sensors
Data Source
AI summary
An in-line pipe inspection tool has a sensor carrier carrying a plurality of sensor for monitoring the pipe. In order to permit the sensor carrier and hence the sensors, to conform to changes in the diameter of the pipe being inspected, the sensor carrier is a part cylindrical body which is resiliently flexible. However, to stop one part of the sensor carrier twisting torsionally relative to another part, a bracing unit is fixed to one part the sensor carrier and engages another part of the sensor carrier to resist said torsional twisting.