Heat Exchanger Measuring Device Sensor Segmentation
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Solution Overview
Problem
Existing heat exchanger monitoring systems require a large number of heat flow sensors, leading to high costs and potential gaps in heat flow monitoring, which can result in delayed detection and cleaning of deposits.
Innovation Solution
A measuring device with at least one heat flow sensor on the firing side and one additional temperature sensor on the insulation side, arranged on a web, allows for the determination of two heat flows using only one additional temperature sensor, reducing sensor costs and improving monitoring capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a large number of heat flow sensors are used to monitor pressure pipe arrangements, then measurement precision and detection capability improve, but device complexity and costs increase significantly
Solution Approach 1:
The monitoring system is segmented into two functional parts: heat flow sensors that measure heat flow directly, and temperature sensors that measure temperature at specific locations. By segmenting the measurement functions and using different sensor types with different placement requirements, the system achieves comprehensive monitoring with fewer total sensors.
Solution Approach 2:
Temperature sensors serve as intermediaries that indirectly provide heat flow information through temperature measurements. By placing temperature sensors on webs at strategic locations and using heat conduction principles to calculate heat flows, the system obtains additional heat flow data without requiring additional heat flow sensors at every location.
2Measurement precision
If heat flow sensors are placed on the firing side of pressure pipes, then detection capability improves, but temperature sensors are exposed to high thermal load reducing their lifespan
Solution Approach 1:
Different sensor types are assigned to different locations based on local conditions: heat flow sensors are placed on the firing side where they can withstand high temperatures and directly measure heat flow, while temperature sensors are placed on webs where they experience lower thermal loads and can provide temperature data for heat flow calculations.
3Duration of action of stationary object
If temperature sensors are arranged on the insulation side at a distance from heat flow sensors, then thermal load on temperature sensors is reduced extending their lifespan, but measurement precision may be compromised
Solution Approach 1:
The solution moves the temperature sensors from the traditional position on the pressure pipe surface to the webs that connect the pressure pipes. This spatial repositioning in a different dimension (from pipe surface to connecting web structure) allows temperature sensors to be closer to the heat flow measurement locations while experiencing reduced thermal load, enabling accurate heat flow calculation through the web structure.
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 configuration enables efficient monitoring of heat flows with fewer sensors, reducing thermal load on temperature sensors and allowing for precise calculation of heat flows, thereby detecting deposits and contamination effectively, while extending sensor lifespan and reducing operational costs.
Implementation Method 1
a heat flow sensor (5) which is arranged on the furnace side in such a way that at least two temperatures T1 and T2 and their temperature difference can be determined there
Implementation Method 2
at least one temperature sensor for measuring a temperature T3 is additionally arranged on the insulation side and at a distance from the heat flow sensor
Data Source
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AI summary
The present invention relates to a measuring device (1) for a heat exchanger (2) that comprises a pressure pipe arrangement (10) that is spaced using webs (11) and that has a heating side (8) and an isolation side (9) and that is implemented with at least one heat flow sensor (5), wherein the heat flow sensor (5) is arranged on the heating side (8) in such a way that at least two temperatures T1 and T2 and the temperature difference thereof can be detected there, and additionally at least one temperature sensor (16) for measuring a temperature T3 is arranged on the isolation side (9) and at a distance to the heat flow sensor (5).