Infrared Sensor Array Diagnostics for Continuous Process Leak Detection

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Solution Overview

Problem

Industrial process monitoring systems face challenges in continuously detecting leaks and anomalies, as manual inspection with handheld thermal imaging cameras is time-consuming and does not provide continuous monitoring.

Innovation Solution

A diagnostic field device equipped with an infrared sensor array and processing circuitry generates thermal images, allowing for automated comparison of infrared emissions from different subsections to identify anomalies, such as leaks, without requiring operator intervention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual inspection with handheld thermal imaging cameras is used, then thermal anomalies can be detected, but continuous monitoring cannot be provided and inspection is time-consuming

Engineering Contradiction:

Improveinspection speedVSAvoidautomation level

Core Design Contradiction:

ProductivityVSExtent of automation

Solution Approach 1:

The patent replaces manual mechanical inspection with an automated infrared sensing system. The sensor array automatically captures thermal images and the processing circuitry automatically analyzes temperature variations, eliminating the need for manual operation of handheld cameras and providing continuous automated monitoring capability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The diagnostic field device performs self-monitoring and self-diagnosis by automatically comparing temperature variations across different zones of the process equipment. The system identifies potential issues through automated analysis of thermal patterns without requiring external operator intervention for each inspection cycle

Inventive Principle:

Principle #25Self-service

2Extent of automation

If automated infrared sensing is implemented, then continuous monitoring is provided, but device complexity increases

Engineering Contradiction:

Improveautomation levelVSAvoidsystem complexity

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The patent divides the inspection task into segmented zones across the process equipment surface. The sensor array captures thermal data from multiple discrete zones that are independently analyzed, allowing complex monitoring to be broken down into simpler, manageable comparison operations between adjacent zones

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The diagnostic field device is designed as a universal monitoring system that can detect multiple types of anomalies (leaks, overheating, insulation failures) using the same infrared sensing and comparison methodology, eliminating the need for multiple specialized devices and reducing overall system complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If manual interpretation of thermal images is used, then diagnostic capability is provided, but time is lost and continuous monitoring is not achieved

Engineering Contradiction:

Improvedetection reliabilityVSAvoidinspection time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent replaces manual interpretation of thermal images with automated processing circuitry that continuously analyzes temperature variations. The system automatically compares thermal signatures across different zones and identifies anomalies in real-time, eliminating the time loss associated with manual inspection while maintaining diagnostic reliability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The diagnostic system operates continuously by constantly monitoring thermal patterns and immediately detecting deviations from normal temperature variations. This continuous automated analysis eliminates idle time between inspections and provides uninterrupted surveillance of process equipment conditions

Inventive Principle:

Principle #20Continuity of useful action

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 solution enables continuous monitoring and rapid detection of thermal anomalies, reducing the likelihood of false alarms and improving safety by identifying issues like leaks and overheating without the need for manual inspection.

Implementation Method 1

an infrared sensor array having a plurality of infrared sensors arranged to sense infrared emissions from a location in the industrial process

Methodology Applied

Scientific EffectInfrared radiation detection: Infrared Radiation

Data Source

PatentUS11076113B2Industrial process diagnostics using infrared thermal sensing

Publication Date: 2021.07.27 ROSEMOUNT INC

AI summary

A diagnostic field device for identifying a diagnostic condition in an industrial process includes an infrared sensor array having a plurality of infrared sensors arranged to sense infrared emissions from a location in the industrial process. Processing circuitry processes outputs from the plurality of infrared sensors of the sensor array and generates an infrared image. Diagnostic circuitry compares processed outputs from at least two subsections of the infrared image and provides a diagnostic output based upon the comparison.