Nested Tube Sensor Structure for High-Pressure Fluid Detection
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Solution Overview
Problem
High-pressure lines in industries face challenges with dynamic pressure loads, leading to rapid wear and a lack of suitable sensors that can withstand and detect fluid parameters under extreme conditions.
Innovation Solution
A sensor design comprising a metal outer tube and inner tube with a frictional connection, where the inner tube is strain-hardened and has a larger elongation, and a signal line and pick-up elements are integrated within grooves or recesses, allowing for pressure resistance up to 22,000 bar and enabling detection of fluid characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor is installed in a high-pressure line to detect fluid parameters, then measurement capability is improved, but the sensor cannot withstand the high pressures and fails
Solution Approach 1:
The sensor is divided into two separate tubular components: an inner tube that contacts the high-pressure fluid and an outer tube that provides structural support. The inner tube can be made from materials suitable for fluid compatibility while the outer tube provides the mechanical strength to withstand high pressures, allowing the sensor to function reliably in high-pressure environments
Solution Approach 2:
The inner tube is nested within the outer tube, creating a concentric arrangement where the inner tube carries the sensing elements and the outer tube provides pressure containment. This nested structure allows both measurement functionality and high-pressure resistance to coexist
2Strength
If the wall thickness of the tube is increased to withstand high pressures, then pressure resistance is improved, but the tube becomes more prone to crack propagation
Solution Approach 1:
The tube wall is segmented into two separate tubes rather than one thick wall. This segmentation allows the inner tube to have optimized wall thickness for fluid contact while the outer tube provides additional structural support, distributing stress more effectively and reducing crack propagation risks
Solution Approach 2:
The dual-tube structure functions as a composite system where the inner and outer tubes work together to provide both pressure resistance and crack propagation resistance. The combination of two tubes with potentially different material properties creates a more reliable structure than a single tube
3Ease of manufacture
If signal lines and pick-up elements are placed on the outer surface of the tube, then manufacturing is simplified, but the sensors are exposed to high pressures and fail
Solution Approach 1:
The signal lines and pick-up elements are placed within the inner tube structure, which is itself nested within the outer tube. This nested arrangement protects the sensitive electronic components from direct exposure to high pressures while maintaining manufacturing feasibility
Solution Approach 2:
The inner tube acts as an intermediary structure that houses the signal lines and pick-up elements, shielding them from the high-pressure environment while allowing them to function. The inner tube mediates between the sensing requirements and the pressure resistance 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 sensor provides enhanced pressure resistance and the ability to detect fluid parameters effectively, reducing wear and improving reliability under high-pressure conditions.
Implementation Method 1
the inner diameter of the outer tube is reduced such that after drawing the outer tube is in frictional connection with the inner tube
Implementation Method 2
by the drawing the inner diameter of the outer tube is reduced
Data Source
AI summary
Sensor for high-pressure line and method for manufacturing thereof. The sensor detects parameters or properties of fluid conducted in a high-pressure line while maintaining the high pressure of the fluid. The sensor includes an inner tube extending concentrically in the outer tube that together form a tube and at least one groove which extends in the inner surface of the outer tube or in the outer surface of the inner tube in a longitudinal direction, at least one signal line arranged in the groove, and at least one pick-up element connected to the signal line and arranged at least in the groove or in at least one recess which is provided at least in the outer surface of the inner tube or in the inner surface of the outer tube in addition to the at least one groove. The outer tube is in frictional connection with the inner tube.