Modular Tank Density Sensor Array for Continuous Measurement
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Solution Overview
Problem
Conventional methods for measuring densities in oil and water mixtures require shutting down the system and emptying the tank to replace malfunctioning sensors, leading to downtime and reduced accuracy.
Innovation Solution
A system with individual sensors at each measuring level, allowing for continuous data transmission and independent replacement or servicing without shutting down the system, along with the ability to rotate sensors for enhanced reading range and clean the nuclear source surface during operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If sensors are placed in a single longitudinal array, then the structure is simple and easy to install, but if a sensor malfunctions the entire array must be removed and the system shut down for replacement
Solution Approach 1:
The patent divides the sensor array into multiple independent sensor units, each capable of independent operation and replacement. This segmentation allows individual sensors to be serviced without removing the entire array or shutting down the system, thus maintaining system availability while keeping the overall structure relatively simple.
Solution Approach 2:
The patent introduces rotational capability to sensors, allowing them to dynamically adjust their orientation. This dynamic feature enables sensors to be rotated into position during replacement without requiring complete array removal, improving maintenance flexibility and system availability.
2Ease of manufacture
If sensors are placed in a single longitudinal array, then installation is straightforward, but tank must be emptied to repair malfunctioning sensor
Solution Approach 1:
By segmenting the sensor array into independent replaceable units with individual access mechanisms, the patent enables sensor replacement without emptying the tank. Each sensor can be accessed and replaced independently through its own access point, eliminating the time loss associated with tank emptying while maintaining installation simplicity.
Solution Approach 2:
The patent incorporates pre-positioned access mechanisms and mounting structures that allow sensors to be quickly removed and replaced without tank emptying. This preliminary preparation of access paths and mounting interfaces enables rapid sensor maintenance while the tank remains operational.
3Productivity
If individual sensors are independently placed, then malfunctioning sensor can be replaced without system shutdown, but device complexity increases
Solution Approach 1:
The patent segments the sensor array into independently addressable and replaceable units, each with its own mounting and access mechanisms. This segmentation enables individual sensor replacement without system shutdown, maximizing on-line time. The modular design keeps complexity manageable through standardization of components.
Solution Approach 2:
The patent employs universal mounting interfaces and standardized sensor units that can be easily replaced. This universality reduces the complexity increase that would otherwise result from individual sensor placement, as the same mounting and access mechanisms can be used across all sensor positions.
4Measurement precision
If sensors are rotated for enhanced reading range, then measurement accuracy improves, but mechanism complexity increases
Solution Approach 1:
The patent incorporates rotational capability into the sensor design, allowing sensors to dynamically adjust their orientation to optimize measurement angles. This dynamic adjustment improves measurement precision by enabling sensors to read at multiple angles, including through tank walls at optimized orientations. The rotation mechanism is integrated into the modular sensor unit, keeping overall complexity manageable.
Solution Approach 2:
By integrating the rotation mechanism into individual sensor units rather than the entire array, the patent localizes the complexity increase. Each sensor module becomes slightly more complex, but the overall system complexity remains manageable through modular design and standardization of the rotation mechanisms across all sensors.
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 approach increases on-line time, minimizes downtime, enhances accuracy, enables in-service cleaning, and allows for flexible detector placement, resulting in improved operational efficiency and accuracy of density measurements.
Implementation Method 1
Each sensor is comprised of its own nuclear shutoff provision
Data Source
AI summary
A system to completely measure multiple densities in varying levels in tanks or vessels. The present invention provides an individual sensor at each measuring level in the tank, each sensor provided with electronic data to provide continuous density data at leach level. Each sensor is individually placed in the sensor array. If a sensor malfunctions, the individual sensor can be replaced without interrupting the data transmissions or requiring a shutdown of the system to remove the single row array of sensors which are placed together as in the prior art. Each sensor also includes a cooling pipe to cool components with recirculating water.