Method for calculating the stability of a procedural apparatus with fluid flowing through it
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Solution Overview
Problem
Current methods for determining mechanical stresses in process engineering apparatuses, such as heat exchangers, are imprecise and often require offline, time-consuming calculations, limiting real-time monitoring and maintenance efficiency.
Innovation Solution
A method utilizing a large number of temperature sensors to record temperature measurements across various points in the apparatus, which are then used as boundary conditions in a finite element method for precise stress calculations, incorporating a self-learning algorithm to reuse and interpolate previous results for accurate service life analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If temperature comparison with threshold values is used to monitor thermal stress, then device damage can be prevented, but measurement precision and stress determination accuracy deteriorate
Solution Approach 1:
The patent replaces the mechanical/physical measurement system (temperature sensors and threshold comparison) with a computational model (finite element method) that calculates actual stress values. This substitution enables precise stress determination while maintaining reliability in preventing device damage.
Solution Approach 2:
The patent changes the monitoring parameter from temperature (indirect indicator) to actual stress values (direct measurement). By using the finite element method to calculate stress based on temperature distribution, the system achieves precise stress determination instead of relying on imprecise temperature threshold comparisons.
2Measurement precision
If finite element method with temperature measurements is used for stress calculation, then stress determination precision improves, but computational complexity and time requirement increase
Solution Approach 1:
The patent performs preliminary actions by pre-processing temperature measurements and preparing boundary conditions before executing the finite element method. This preparation work is done offline, allowing the actual stress calculation to be performed efficiently with reduced computational complexity during real-time monitoring.
Solution Approach 2:
The system uses the temperature measurements from the monitoring system itself as input for the finite element method, making the system self-sufficient. The same temperature data used for basic monitoring is also utilized for precise stress calculation, eliminating the need for separate measurement systems and reducing overall complexity.
3Measurement precision
If offline stress determination is performed, then computational accuracy improves, but real-time monitoring capability deteriorates
Solution Approach 1:
The patent performs preliminary calculations and model setup offline to ensure computational accuracy, then uses these pre-prepared models for rapid real-time stress determination during operation. This separation of offline preparation and online execution enables both high accuracy and real-time monitoring capability.
Solution Approach 2:
The system dynamically adapts the finite element method for real-time application by using pre-computed models and simplified calculation pathways for online stress determination. The methodology transitions from static offline analysis to dynamic real-time monitoring while maintaining accuracy through the use of pre-prepared computational frameworks.
Data Source
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AI summary
The invention relates to a method for calculating the strength and the service life of a process apparatus through which fluid flows, wherein: temperatures existing at a plurality of different points of the apparatus are measured at a first time point in order to obtain temperature measurement values (201); the temperature measurement values are used as constraints in a finite element method (203) in order to determine mechanical stresses existing at a plurality of different points in the material of the apparatus as stress values (204); the remaining service life of the material of the apparatus is determined from the obtained stress values (205); the remaining service life of the material of the apparatus is determined also in dependence on data regarding the apparatus that were determined at a second time point (207), which second time point is earlier than the first time point.