Modular Heater System With Hinged Carrier Members
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Solution Overview
Problem
The existing methods for installing and replacing electric heat trace cables in pipelines are time-consuming and burdensome, especially in utility lines and continuous manufacturing processes, and pre-fabricated heat-traced pipes require custom-made solutions, increasing inventory costs and space.
Innovation Solution
A heater system comprising hinged carrier members with resistive heating elements and end fittings, where the carrier members are designed for close proximity with the heating target and provide tactile feedback during installation, allowing for efficient heat transfer and reduced installation time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If heat trace cables are fastened to conduits with bands or straps, then the heating function is provided, but the installation process becomes time-consuming and burdensome
Solution Approach 1:
The heater system is divided into multiple modular sections, each comprising a carrier member with integrated fastening features. These sections can be independently installed and connected, eliminating the need for time-consuming continuous fastening operations while maintaining reliable heating coverage along the conduit.
Solution Approach 2:
The carrier member integrates multiple functions into a single component: it holds the heat trace cable, provides attachment features for securing to the conduit, and includes end fittings for electrical connections. This consolidation eliminates the need for separate bands, straps, and mounting hardware, significantly reducing installation time.
2Loss of time
If pre-fabricated heat-traced pipes are used to expedite replacement, then installation time is reduced, but inventory space and manufacturing costs increase
Solution Approach 1:
The heater system is provided as separate modular sections rather than requiring complete pre-fabricated pipes. These sections can be manufactured in advance and stored compactly, then quickly assembled on-site to replace heated conduit sections, reducing both inventory requirements and manufacturing costs while maintaining fast replacement capability.
Solution Approach 2:
The modular heater sections are designed with standardized interfaces and universal mounting features that can accommodate various conduit sizes and configurations. This universality allows a single inventory of heater sections to serve multiple replacement scenarios, eliminating the need for custom-made solutions for each specific pipe replacement task.
3Manufacturing precision
If custom-made heat-traced pipes are manufactured for each replacement task, then precise fit is achieved, but inventory costs and space requirements increase
Solution Approach 1:
The heater system uses standardized modular sections that can be combined in different lengths and configurations to match various conduit sizes. This segmentation allows a limited inventory of standard sections to serve multiple custom fit requirements, eliminating the need to manufacture and store custom-made pipes for each specific application.
Solution Approach 2:
The modular carrier members are designed with adjustable or variable parameters such as flexible mounting positions, adaptable end fittings, and configurable section lengths. These parameter variations allow the same basic heater section design to achieve precise fit for different conduit configurations without requiring custom manufacturing, thereby reducing inventory space requirements.
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 system enables faster and more efficient installation of electric heaters in pipelines by providing tactile feedback and efficient heat transfer, reducing installation time and inventory costs associated with custom-made solutions.
Implementation Method 1
A plurality of resistive heating elements are disposed within the outer receiving portions of the hinged carrier members
Implementation Method 2
The inner periphery surfaces of the hinged carrier members are adapted for close proximity with a heating target
Data Source
AI summary
A heater system is provided that includes a plurality of carrier members, each carrier member defining an inner periphery surface, an outer receiving portion, and connecting portions. A plurality of resistive heating elements are disposed within the outer receiving portions of the carrier members, and end fittings are disposed proximate the carrier members and the resistive heating elements. A cover is disposed around the carrier members and the resistive heating elements, and the inner periphery surfaces of the carrier members are adapted to transfer heat to a target and the connecting portions are adapted to be secured to at least one of an adjacent carrier member and a heating target. In one form, at least one set of a carrier member and a resistive heating element are resiliently movable such that the heater system provides tactile feedback to an installer that the heater system is properly installed around a target.