Gas Sensor Testing System with Recycle Circuit
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Solution Overview
Problem
Gas sensors require frequent testing with pressurized test gas, leading to fugitive emissions and depletion of available test gas, as the gas escaping from tubing after each usage increases, necessitating frequent refilling of test bottles.
Innovation Solution
A system and method for recapturing test gas used during sensor testing, utilizing a supply circuit with a compressor to direct the test gas back to the source, reducing waste and extending the life of test gas supplies by integrating a recycle circuit and a filter to prevent ambient air contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If test gas is delivered through tubing to the sensor, then the gas sensor can be tested, but test gas escapes into the atmosphere and depletes the test gas supply
Solution Approach 1:
The patent implements a recapture system that collects test gas after it has been used to test the sensor. The recapture line draws gas from the sensor outlet and returns it to the test gas source, allowing the same test gas to be reused multiple times. This recovering approach directly addresses the test gas depletion problem while maintaining reliable sensor testing capability.
Solution Approach 2:
The system maintains continuous circulation of test gas through the recapture mechanism. Instead of allowing test gas to escape after each use, the recapture line continuously draws gas back to the source, enabling uninterrupted and repeated testing operations without depleting the test gas supply.
2Loss of substance
If a recapture system is added to recover test gas, then test gas depletion is reduced, but the device complexity increases
Solution Approach 1:
The patent introduces a recapture line as an intermediary component that connects the sensor outlet back to the test gas source. This simple intermediary element enables test gas recovery without requiring complex machinery, achieving the balance between reducing test gas depletion and maintaining system simplicity.
Solution Approach 2:
The system extracts only the essential function needed for recapture - a simple line or tube to transport gas from the sensor outlet back to the source. By taking out only what is necessary rather than implementing a complex recirculation system, the patent minimizes added complexity while effectively reducing test gas depletion.
3Productivity
If test gas is continuously supplied to the sensor, then frequent testing can be performed, but fugitive emissions increase
Solution Approach 1:
The recapture system recovers test gas that would otherwise be emitted into the atmosphere. By collecting and returning this gas to the source, the system enables frequent testing operations without proportionally increasing fugitive emissions, thus improving productivity while controlling harmful emissions.
Solution Approach 2:
The patent converts the potentially harmful fugitive emissions into a beneficial resource by recapturing the test gas and returning it to the source. What would have been waste and pollution becomes a reusable asset, allowing high testing throughput without proportional increase in harmful emissions.
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
The solution significantly reduces fugitive emissions, preserves test gas for multiple sensor tests without refilling, and enhances workplace safety by efficiently recycling test gas, allowing for extended usage without depleting the test gas supply.
Implementation Method 1
a compressor with a compressor inlet that is in selective communication with the supply circuit
Implementation Method 2
a filter is in the supply circuit that contains an air blocking material
Implementation Method 3
the test cap includes a chamber that receives the sensor inlet, and seals on the inner surface of the chamber that define a pressure barrier between the test gas in the supply circuit and ambient
Data Source
AI summary
A system and method for testing a gas sensor with a test gas and that recovers the test gas after testing. The test gas is stored in a test gas source, and delivered to the gas sensor through a supply circuit. After the test is completed, gas is withdrawn from the supply circuit into a recycle circuit. A compressor in the recycle circuit pulls the test gas into the recycle circuit, pressurizes the test gas and discharges the pressurized test gas back into the test gas source. Valves are in the supply and recycle circuits, which when selectively opened and closed changes between testing and recycle configurations. The recycle flow is filtered to prevent air and other non-test gas substances from being introduced into the test gas source.