Leak Detection Device with Additive Monolithic Conduit
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Solution Overview
Problem
Existing leak detection systems in powered systems, such as vehicles, face challenges in efficiently collecting and directing high-pressure fluid leaks due to complexity and the risk of additional leaks, with current solutions being costly and prone to overfilling or failure points.
Innovation Solution
A leak detection device with an additively manufactured body featuring a fluid input, drain, and sensor conduit input, including an internal conduit with a reduced flow portion, allowing for efficient accumulation and sensing of leaks while preventing overfilling, and optionally featuring multiple drains and sensors for enhanced detection capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a closed tank with inlet is used to collect leaking fluid, then the tank can detect leaking fluid through a sensor, but the tank can only collect a fixed amount of leaking fluid and quickly becomes overfilled with faster leaks
Solution Approach 1:
The internal conduit is segmented into multiple branches (first branch receiving from fluid input, second branch receiving from sensor conduit input, third branch extending to drain) that operate independently to manage different aspects of fluid collection and detection, allowing continuous operation without overfilling
Solution Approach 2:
The reduced flow portion acts as an intermediary element that controls and regulates fluid flow between the input/conduit and drain, creating a bottleneck that prevents overfilling while maintaining detection capability
2Productivity
If an orifice drain is added to direct accumulated fluid back to fuel tank, then the tank can handle faster leaks, but the tank typically does not have common parts and is expensive to manufacture
Solution Approach 1:
The device merges multiple functions (collection, detection, drainage, flow control) into a single integrated body with internally formed conduits, eliminating the need for separate components and reducing manufacturing complexity and cost
Solution Approach 2:
The mechanically complex multi-component tank system is replaced with an additively manufactured monolithic structure where conduits are formed directly within the body, simplifying manufacturing and reducing part count
3Measurement precision
If a complex web of conduits and fittings is used to collect and direct leaks, then leak detection capability is enhanced, but the system adds to the number of failure points where additional leaks may occur
Solution Approach 1:
Multiple conduits are merged and integrated within the monolithic body structure, reducing the number of external connections and fittings that could become failure points while maintaining comprehensive leak collection and detection capability
Solution Approach 2:
The internal conduits are nested within the body structure, with conduits contained within the solid material of the body itself, eliminating the need for separate external conduit assemblies and reducing potential failure points
4Device complexity
If traditional manufacturing methods are used for leak detection tanks, then the structure can be simple, but the system is overly complex and expensive when incorporating multiple components
Solution Approach 1:
Traditional mechanical assembly of multiple components is replaced with additive manufacturing technology that creates complex internal geometries directly within a monolithic structure, simplifying the manufacturing process while maintaining structural integrity
Solution Approach 2:
The manufacturing approach is changed from traditional subtractive or assembly-based methods to additive manufacturing, enabling complex internal conduit structures to be created efficiently at lower cost
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
The device effectively directs and senses fluid leaks, preventing overfilling and reducing the risk of additional leaks, while being relatively inexpensive to manufacture and customize, offering improved reliability and efficiency in leak detection and management.
Implementation Method 1
The lower branch of the internal conduit includes a reduced flow portion having a smaller cross-sectional size than the upper branch of the internal conduit. The internal conduit has the reduced flow portion below the at least one fluid input and the at least one sensor conduit input but above the at least one drain.
Implementation Method 2
The lower branch of the internal conduit includes a reduced flow portion having a smaller cross-sectional size than the upper branch of the internal conduit.
Data Source
AI summary
A leak detection device includes a body having at least one fluid input that receives a fluid leak, at least one drain fluidly coupled with a container, and at least one sensor conduit input fluidly coupled with at least one sensor. The fluid input is located above the drain but below the sensor conduit input. The body includes an internal conduit that is fluidly coupled with and extends between the fluid input, the drain, and the sensor conduit input. The internal conduit includes a lower branch that extends below the fluid input to the drain. The internal conduit includes an upper branch that separately extends in the body above the sensor conduit input to the drain. The lower branch includes a reduced flow portion below the fluid input and the sensor conduit input but above the drain.