Closed System Fluid Loss Quantification via Dynamic Pressure Control
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Solution Overview
Problem
Existing methods for quantifying gas leak rates in aerospace applications are inefficient, requiring repetitive testing, being temperature-sensitive, and unable to calculate mass loss and measurement uncertainty in real-time, with high uncertainty and long test durations due to variable pressure conditions and limited gas types.
Innovation Solution
A system that maintains a constant pressure differential across a test article using a microcontroller and pressure regulator, allowing real-time calculation of gas leak rates and uncertainty, using low-cost hardware and reducing statistical variance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional pressure decay methods are used with variable pressure conditions, then measurement can be performed with simple equipment, but test duration becomes excessively long and measurement uncertainty is high
Solution Approach 1:
The system dynamically adjusts the downstream pressure to maintain a constant pressure differential across the test article throughout the test duration. This is achieved through a controlled pressure system that responds to real-time pressure measurements, transforming the static pressure decay method into a dynamic process that actively compensates for pressure changes, thereby reducing test duration while maintaining measurement precision
Solution Approach 2:
The system implements a feedback control mechanism where pressure sensors continuously monitor the pressure differential and provide real-time data to a microcontroller. The microcontroller adjusts the downstream pressure based on this feedback to maintain the desired constant differential, enabling real-time calculation of leak rates with reduced uncertainty and shorter test durations
2Reliability
If multiple repetitive tests are conducted to achieve statistical significance, then measurement reliability improves, but time consumption and cost increase
Solution Approach 1:
The system enables continuous data collection throughout the test duration by maintaining a constant pressure differential, ensuring that all collected data points are valid and contribute to the statistical analysis. This eliminates the need to discard data from tests where pressure differential drifted, allowing single tests to achieve the statistical significance that previously required multiple repetitive tests
Solution Approach 2:
The invention replaces the mechanical approach of conducting multiple physical tests with a control system approach that uses sensors, microcontrollers, and automated pressure adjustment. This substitution enables real-time monitoring and control, allowing statistical significance to be achieved through improved data quality from a single test rather than through repetition
3Measurement precision
If constant pressure differential is maintained through controlled pressure system, then real-time calculation accuracy improves and test duration reduces, but device complexity increases
Solution Approach 1:
The system introduces a microcontroller as an intermediary that acts as the intelligence center, coordinating between pressure sensors, controlled pressure systems, and data processing functions. This centralized intermediary simplifies the overall system architecture by consolidating control logic and enabling real-time calculations without requiring complex distributed control mechanisms
Solution Approach 2:
The system implements self-service through automated feedback control where the microcontroller automatically adjusts downstream pressure based on real-time measurements to maintain constant differential. This self-regulating mechanism eliminates the need for manual intervention and complex external control systems, achieving high measurement precision with relatively simple device architecture
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 shortens test durations, eliminates redundant data collection, and provides quantifiable and controllable measurement uncertainty, improving test efficiency and reducing project costs and schedules.
Implementation Method 1
a pressure controlled system having a second pressure, wherein the second pressure is lower than the first pressure, thereby creating a predetermined pressure differential between the first pressure and the second pressure; a means for controlling the second pressure to maintain the predetermined pressure differential as the fluid is lost from the nominally closed system across the test article
Implementation Method 2
silicone seals have a high relative leak rate due to the permeability of these silicone compounds
Implementation Method 3
The apparatus is pressurized with an ideal gas until the pressure is slightly above a desired differential pressure, which is then allowed to leak from a high pressure side through the test article to a low pressure side
Data Source
AI summary
In various embodiments, the present invention provides an improved apparatus and method for quantification of fluid loss from a nominally closed system using a pressure decay with mass point leak rate analysis methodology, which avoids the need for repetitive testing due to test configuration incompatibilities and allows for real time analysis and test control based upon desired results. The novel apparatus and methods of the present invention utilize a control system to maintain a desired pressure differential across the test article throughout the test by automatically raising or lowering the downstream pressure as the fluid leaks through the test article. In various embodiments, the apparatus and method of the present invention improves the efficiency of existing test methods by shortening otherwise long test durations, right-sizing the amount of data collected, providing quantifiable and controllable measurement uncertainty, reducing statistical variance, and eliminating post-process data analysis.