IoT Gas Tank Aging Detection for Predictive Maintenance
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Solution Overview
Problem
Gas tanks are exposed to environmental factors that lead to aging and corrosion, reducing their service life and posing safety risks, with manual inspections being labor-intensive and prone to inaccuracies.
Innovation Solution
An IoT system comprising a smart gas user platform, service platform, device management platform, sensor network platform, and object platform, utilizing machine learning models to predict gas tank aging and damage, and automate maintenance planning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection is used to check gas tank conditions, then inspection accuracy can be maintained through expert judgment, but labor time costs increase and safety risks arise from high-altitude work
Solution Approach 1:
The patent replaces manual mechanical inspection with an automated inspection system comprising cameras, sensors, and image processing algorithms. The system captures images of the gas tank surface and uses computer vision technology to automatically detect cracks, corrosion, and other defects, eliminating the need for manual high-altitude inspection while maintaining or improving detection accuracy.
Solution Approach 2:
The patent introduces an intermediary inspection system that acts as a mediator between the gas tank and human operators. This system includes inspection platforms, imaging devices, and data processing systems that collect and analyze tank conditions, then present processed information to operators, thereby eliminating direct human exposure to hazardous environments while preserving inspection capabilities.
2Reliability
If comprehensive manual inspection is performed to ensure safety, then detection accuracy can be improved, but the complexity and cost of operations increase
Solution Approach 1:
The patent divides the gas tank inspection system into multiple independent modules: imaging modules for capturing images, sensing modules for detecting physical parameters, processing modules for analyzing data, and control modules for coordinating operations. Each module performs a specific function, allowing for specialized optimization while reducing overall operational complexity through modular architecture.
Solution Approach 2:
The patent designs a multi-functional inspection system that can simultaneously perform multiple inspection tasks including visual inspection, dimensional measurement, and material property detection. The system can inspect different types of gas tanks (stored or in service) using the same platform, reducing operational complexity through universal application.
3Ease of operation
If gas tanks are placed in open air for storage and distribution, then accessibility and operation convenience are improved, but environmental factors cause aging and corrosion that reduce service life
Solution Approach 1:
The patent applies preliminary protective measures to gas tanks before they are exposed to environmental factors. This includes pre-application of anti-corrosion coatings, corrosion inhibitors, and protective films during manufacturing or initial installation. The system also performs regular predictive maintenance based on environmental exposure data to address potential corrosion issues before they compromise structural integrity.
Solution Approach 2:
The patent implements a feedback system that continuously monitors environmental conditions (temperature, humidity, pollution levels) and tank condition (corrosion rate, coating integrity). This feedback is used to adjust maintenance schedules, apply protective measures when degradation is detected, and predict remaining service life, thereby extending tank durability while maintaining open-air placement.
Data Source
AI summary
The embodiments of the present disclosure provide a method and Internet of Things (IoT) system for maintaining and managing a storage and distribution station of smart gas. The method may be executed by a smart gas device management platform of the IoT system for maintaining and managing the storage and distribution station of smart gas. The method may include: obtaining gas tank data and gas tank environmental data of a target gas tank of a gas storage and distribution station; obtaining image data of the target gas tank, and predicting gas tank aging data of the target gas tank based on the image data; predicting, based on the gas tank aging data, the gas tank data, and the gas tank environmental data, gas tank damage data of the target gas tank; and determining a maintenance plan of the target gas tank based on the gas tank damage data.