Gas Distribution Flow Path Malfunction Detection and Localization
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Modern gas distribution systems (GDSs) face challenges in detecting malfunctions and irregularities, which can lead to incorrect assembly, component degradation, and disruptions in manufacturing processes, resulting in increased operational costs, reduced product quality, and safety concerns.
Innovation Solution
A method and system for detecting malfunctions in GDSs by enabling gas flow through a flow path, receiving pressure and flow rate data, processing this data to identify malfunctions, determining the relative location of the malfunction, and generating a report indicating the presence and location of any detected malfunctions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual testing is performed to detect malfunctions in gas distribution systems, then detection capability is provided, but time consumption and error proneness increase
Solution Approach 1:
The patent replaces manual mechanical testing with an automated electronic system that uses sensors to detect pressure and flow rate data, and a controller to process this data and identify malfunctions. This substitution eliminates human error and reduces testing time while maintaining or improving detection accuracy.
Solution Approach 2:
The system enables the gas distribution system to self-diagnose malfunctions by automatically collecting data from sensors, processing it through a controller, and generating reports without requiring manual intervention. This self-service capability reduces both time consumption and human error in the detection process.
2Reliability
If comprehensive manual testing is performed on gas distribution systems, then malfunction detection is achieved, but operational disruption increases
Solution Approach 1:
The automated testing system can operate continuously or periodically without requiring system shutdown, allowing the gas distribution system to maintain continuous operation. The sensors continuously monitor pressure and flow rate data, enabling malfunction detection without interrupting the manufacturing process, thus preserving both system integrity and productivity.
3Loss of time
If automated detection systems are implemented in gas distribution systems, then testing time is reduced, but system complexity increases
Solution Approach 1:
The controller serves multiple functions: it receives data from multiple sensors, processes this data to detect various types of malfunctions, determines the location of malfunctions, and generates comprehensive reports. This multi-functionality reduces the need for separate dedicated components for each task, thereby minimizing the increase in system complexity while achieving rapid automated detection.
Data Source
AI summary
Systems and methods for monitoring and detecting a malfunction within a gas distribution system are provided. A system may first enable, by a controller, gas flow through a flow path of the gas distribution system. Afterwards, the system may receive data including pressure data and/or flow rate data associated with the flow path of the gas distribution system while gas flow is enabled through the flow path. The system may process the data to determine whether the first flow path of the gas distribution system includes a malfunction. Responsive to determining that the flow path includes a malfunction, the system may determine a relative location of the malfunction within the flow path, with respect to a mass flow controller (MFC) or sensor within the flow path. The system may generate a report indicating whether the flow path includes a malfunction and a relative location of any determined malfunction.