Automated Leak Detection in Heat Exchanger Tubes Using 3D Sensor Data
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Solution Overview
Problem
Manual leak detection in heat exchanging devices is time-consuming and prone to errors due to human subjectivity, often missing critical testing areas in heat exchanger components like fluid guiding tubes.
Innovation Solution
A 3D sensor captures a cloud of points representing the outer surface of the device, identifying areas of interest like tube connections or changes in diameter, and calculates an approach path for a sniffing probe to ensure thorough and accurate leak detection, potentially automated by a robot.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual leak detection is performed by human operators, then the detection process can be performed with simple equipment, but the detection is time-consuming and prone to human error
Solution Approach 1:
The patent replaces the manual mechanical probing system with an automated robotic system. The robotic arm equipped with a sniffing probe automatically positions and moves the probe to testing areas based on 3D sensor data, eliminating manual operation while maintaining detection capability. This substitution resolves the contradiction by providing both high speed (automated movement) and high reliability (programmed precision).
Solution Approach 2:
The system performs self-positioning and self-detection through the robotic arm that automatically navigates to identified testing areas without human intervention. The robot independently executes the leak detection process based on pre-acquired 3D model data, achieving both efficiency and accuracy through autonomous operation.
2Reliability
If manual probe movement is used, then equipment complexity is low, but it is difficult to verify complete coverage of all testing areas
Solution Approach 1:
The system incorporates feedback through the 3D sensor that continuously monitors probe position relative to the heat exchanger model. The 3D sensor captures the actual position of the sniffing probe and compares it with the planned testing areas, providing feedback to ensure complete coverage. This feedback mechanism guarantees reliable testing area coverage while the automated system manages the complexity.
Solution Approach 2:
The patent creates a digital 3D copy or model of the heat exchanger using 3D sensors. This virtual model serves as a reference for planning and verifying the detection process. By working with the digital copy rather than directly manipulating the physical device, the system achieves precise coverage verification without proportionally increasing physical complexity.
3Productivity
If automated robotic detection is implemented, then detection speed and accuracy improve, but device complexity increases
Solution Approach 1:
The system performs preliminary actions by acquiring 3D sensor data and creating a digital model of the heat exchanger before the actual leak detection begins. Testing areas are identified and the robotic path is planned in advance based on this pre-acquired information. This preliminary preparation enables the automated detection to proceed efficiently with reduced real-time complexity.
Solution Approach 2:
The 3D sensor and digital model serve as intermediaries between the robotic system and the physical heat exchanger. Rather than the robot directly interacting with the complex physical device, it interacts with a simplified digital representation. This intermediary layer manages the complexity by translating physical geometry into programmable coordinates and paths.
Data Source
AI summary
Method for detecting a leak in a fluid guiding element 16, 18 of a heat exchanging device 12, comprising the following steps:a) Acquiring a cloud of points 44 of the heat exchanging device 12 in a three-dimensional virtual space 48 using a 3D sensor 34, each of said points representing a surface point 46a on the outer surface of the heat exchanging device 12, b) Searching within the cloud of points 44 for structures 50 corresponding to tubes having a predefined outer diameter,c) Searching the obtained structures 50 for an area of interest 52 where the diameter or the direction of the tube changes,d) Once an area of interest 52 is found, determining an approach path 58 for approaching a sniffing probe 22 of a gas leak detector 24 to the area of interest 52 within the cloud of points 44, ande) Physically approaching the sniffing probe 22 to a testing area 20 of the heat exchanging device 12 automatically along the approach path 58, where the testing area 20 corresponds to the area of interest 52 within the cloud of points 44.