Movable Fluid Conduit Component Monitoring for Predictive Replacement
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Solution Overview
Problem
Current monitoring systems for movable metal components in fluid lines are inefficient, leading to unnecessary complexity and premature replacement, resulting in increased costs and potential errors in safety-critical industrial applications.
Innovation Solution
A monitoring system comprising a movable metal component with integrated measuring elements, an evaluation unit, and a cloud platform for data collection and analysis, enabling real-time monitoring of state parameters such as temperature, pressure, and vibrations, allowing for extended replacement intervals and optimized maintenance planning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If standardized calculations with safety margins are used to design movable components, then reliability is improved, but device complexity and costs increase
Solution Approach 1:
The patent implements a monitoring system with sensors that continuously measure actual operating conditions (temperature, pressure, displacement, cycles) and feed this data back to an evaluation unit. This feedback mechanism enables real-time assessment of component status, allowing replacement based on actual wear rather than conservative estimates, thereby maintaining reliability while reducing unnecessary safety margins and complexity
Solution Approach 2:
The patent replaces traditional mechanical design approaches based on standardized calculations with a data-driven monitoring and evaluation system. Instead of relying on mechanical safety factors and oversizing components, the system uses sensors and algorithmic evaluation to dynamically assess component health, substituting mechanical redundancy with intelligent monitoring
2Reliability
If close-meshed inspection is implemented, then reliability is improved, but loss of time and productivity decrease
Solution Approach 1:
The monitoring system operates continuously without interrupting the operational process. Sensors continuously collect data on temperature, pressure, displacement, and cycle counts, providing uninterrupted monitoring of component condition. This eliminates the need for periodic shutdowns and manual inspections, maintaining continuous production while ensuring component reliability through real-time surveillance
Solution Approach 2:
The system enables self-monitoring of component condition through integrated sensors and automated evaluation. The movable component essentially monitors itself, with sensors detecting its own operating parameters and the evaluation unit assessing its condition based on accumulated data, eliminating the need for external inspection personnel and manual checks
3Reliability
If premature replacement is performed, then reliability is improved, but loss of substance and costs increase
Solution Approach 1:
The system performs preliminary assessment of component condition by continuously accumulating operational data (temperature exposure, pressure cycles, displacement ranges) and evaluating wear trends before failure occurs. The evaluation unit predicts remaining service life based on accumulated data, allowing planned replacement at the optimal moment rather than premature replacement, thus reducing waste while maintaining reliability
Data Source
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AI summary
The present invention relates to a monitoring system for monitoring the operating states of a movable component 1 for compensating for intrinsic movements in a fluid conduit, comprising a movable component 1 made of metal, which is in particular variable in length and/or angularly movable and/or axially movable and/or laterally movable, at least one measuring element 2, 3, 4 associated with the movable component for detecting at least one state parameter of the movable component, as well as an evaluation unit 6 for collecting and evaluating the state parameters detected by the measuring element 2, 3, 4 and provided as measurement data, a communication module 5 for transmitting the measurement data to the evaluation unit 6 and a cloud platform 10 with which the evaluation unit 6 can be connected as required.The evaluation unit 6 is designed to compare the measurement data received from the communication module 5 with data from the cloud platform 10 or to supplement it with such data, evaluate it and output the results as information and/or to have the measurement data evaluated in the cloud platform 10 and output the results as information.