Intelligent Ball Sensor for Heat Exchanger Tube Health Monitoring

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Solution Overview

Problem

Current methods for assessing heat exchanger health, particularly individual tubes, are labor-intensive and require system shutdown, leading to significant downtime and costs, and do not provide comprehensive monitoring of parameters like flow rates or precise temperature measurements.

Innovation Solution

The use of intelligent ball sensor assemblies with mechanically compliant balls equipped with sensors and signal conditioning control/transmission circuitry, allowing for continuous monitoring of heat exchanger health without shutdown, including assessment of wall thinning, cracking, scaling, and flow rates, and enabling precise determination of temperature measurements within individual tubes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If manual inspection methods (eddy current sensors, ultrasonic probes, video inspection) are used to assess heat exchanger tube health, then measurement precision is improved, but productivity deteriorates due to labor-intensive processes and system shutdown requirements

Engineering Contradiction:

Improvetube health assessment precisionVSAvoidinspection efficiency

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The heat exchanger system performs self-diagnosis by autonomously circulating intelligent balls equipped with sensors through the tube bundle. The system automatically collects data on wall thickness, temperature, flow rates, and structural integrity without requiring external manual intervention, thereby maintaining high measurement precision while dramatically improving inspection productivity and eliminating shutdown requirements

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual mechanical inspection operations with an automated intelligent ball system. The intelligent balls, propelled through the tubes by fluid flow or pumps, carry integrated sensors that automatically measure and transmit data, substituting the need for manual handling of eddy current sensors, ultrasonic probes, and video inspection equipment

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If the heat exchanger system is shut down for comprehensive tube inspection, then measurement precision is improved, but loss of time deteriorates due to system downtime

Engineering Contradiction:

Improvecomprehensive health assessmentVSAvoidsystem downtime

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The intelligent ball inspection system enables continuous operation of the heat exchanger during the inspection process. Multiple intelligent balls can be circulated simultaneously or sequentially through the tube bundle while the system remains operational, allowing comprehensive health assessments to be performed without interrupting the heat exchange process and thus eliminating downtime losses

Inventive Principle:

Principle #20Continuity of useful action

3Measurement precision

If multiple sensors and signal conditioning circuitry are integrated into intelligent balls, then measurement precision and monitoring comprehensiveness are improved, but device complexity increases

Engineering Contradiction:

Improvemulti-parameter monitoring precisionVSAvoidsensor assembly complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The intelligent ball is designed as a universal multi-functional platform that integrates various sensors (ultrasonic, temperature, flow, pressure), signal conditioning circuitry, data processing units, and communication modules into a single self-contained device. This universal design allows the same intelligent ball structure to perform multiple measurement functions simultaneously, improving comprehensive monitoring precision while managing device complexity through functional integration

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

Enables continuous, affordable, and robust monitoring of heat exchanger health, optimizing energy efficiency, scheduling maintenance, and providing data for preventative cleaning, reducing downtime and costs while offering comprehensive health assessments.

Implementation Method 1

the at least one sensor comprises a piezoelectric sensor configured to measure reflected ultrasound intensity

Methodology Applied

Scientific EffectPiezoelectric effect: Piezoelectric Effect

Implementation Method 2

measure reflected ultrasound intensity, which is transmitted to a base station and analyzed upon arrival at a ball trap

Methodology Applied

Scientific EffectUltrasound reflection: Ultrasound

Data Source

PatentUS9903673B1Intelligent ball for monitoring and diagnosis of heat exchanger tube health

Publication Date: 2018.02.27 SENTINEL DIAGNOSTICS LLC

AI summary

An intelligent ball sensor assembly for use with a heat exchanger system, includes a mechanically compliant ball having a recess formed therein. At least one sensor positioned on the ball is configured to gather selected information regarding a heat exchanger system. Signal conditioning control/transmission circuitry is operatively connected to the at least one sensor. A power source is operatively connected to the at least one sensor and the signal conditioning control/transmission circuitry. The sensor and the signal conditioning control/transmission circuitry cooperate to gather information about the status, health and efficiency of the heat exchanger system.