Modular Vacuum Test Chamber Segmentation
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Solution Overview
Problem
Conventional vacuum testing systems require large, fixed-volume chambers that are complex, energy-intensive, and inflexible, leading to increased costs, time delays, and logistical challenges due to the need for large pumps and immobile test facilities.
Innovation Solution
A customizable vacuum test system comprising modular outer shell segments that can be assembled to conform to the shape of a test article, with a porous support layer and zonal barriers to create a sealed enclosure, allowing for efficient evacuation of air and detection of leaks without the need for a dedicated test site.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If large fixed-volume chambers are used to accommodate different test article sizes, then versatility is improved, but device complexity and energy consumption increase
Solution Approach 1:
The vacuum chamber is divided into multiple modular shell segments that can be assembled in different configurations. This allows the chamber volume to be scaled to match the test article size, reducing the volume of air that needs to be evacuated and thereby reducing energy consumption while maintaining versatility across different test article dimensions.
Solution Approach 2:
The chamber transitions from a fixed static structure to a dynamic reconfigurable structure. Shell segments can be assembled and disassembled to create different chamber volumes, allowing the system to adapt its capacity to match the test requirements, thus reducing energy consumption for smaller tests while maintaining the ability to handle larger tests when needed.
2Adaptability or versatility
If large fixed-volume chambers are used, then versatility is improved, but device complexity increases
Solution Approach 1:
The chamber is segmented into standardized modular units that can be assembled like building blocks. This segmentation reduces complexity by breaking down a single complex large-chamber design into multiple simpler, standardized components that can be systematically assembled and disassembled.
Solution Approach 2:
The modular shell segments can be disassembled after use and stored for future tests. This recovering approach reduces the need for permanent installation of large complex structures, allowing the system to maintain versatility while reducing operational complexity by only assembling the necessary chamber size for each specific test.
3Reliability
If thick heavy structural chamber walls are used, then reliability is improved, but weight and immobility increase
Solution Approach 1:
The chamber structure is divided into multiple shell segments with thinner individual walls. When assembled together, these segments form a complete enclosure with adequate structural integrity. The segmentation allows each component to be lighter while maintaining overall reliability through the assembled structure.
Solution Approach 2:
The chamber uses thinner shell segments rather than thick heavy walls. The segmented design provides structural support through the assembly configuration rather than relying on thick individual walls, reducing weight while maintaining the reliability needed for vacuum testing.
4Adaptability or versatility
If large fixed-volume chambers are used, then versatility is improved, but loss of time increases
Solution Approach 1:
The chamber volume becomes dynamic and can be adjusted to match the test article size. This allows the pump-down time to be optimized for each specific test, reducing the time loss associated with evacuating large volumes of air when testing smaller articles, while maintaining the ability to scale up for larger tests when required.
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 solution reduces the volume of air to be evacuated, decreases energy consumption and test time, enables testing at various locations, and enhances safety by minimizing stored energy, while allowing for efficient leak detection and repair.
Implementation Method 1
The porous layer is configured to be located within the interstitial region and to support the inner surface of one or more of the plurality of outer shell segments against an outer side of the test article
Implementation Method 2
The pump is in fluid communication with the interstitial region and configured to evacuate air from within the interstitial region to create a vacuum in the interstitial region
Data Source
AI summary
Systems and methods for customizable vacuum testing chambers. Outer shell segments are assembled to conform to and form a sealed enclosure about a test article having air therein. An interstitial region is defined between the test article and the shell segments. A porous support layer is located within the interstitial region. A vacuum pump evacuates air from within the interstitial region to vacuum test the article. Sensors detect leaks within the interstitial region. Zonal barriers may fluidly isolate zones of the interstitial region for locating leaks. The shell segments may be disassembled and the test article removed. The shell segments may be reused for testing other test articles having different shapes and sizes.