Pressure Vessel Sensor Mounting Rails for In-Field Fatigue Assessment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Pressure vessels have limited lifetimes due to cyclic and static fatigue, with uncertainties in calculating their remaining life, especially when subjected to inconsistent pressure ranges and cycles, and existing sensor systems require laboratory testing, limiting field assessments.
Innovation Solution
A sensor mounting system for pressure vessels that allows in-field testing using phased array Modal Acoustic Emission (PA-MAE) sensors, with rail assemblies and actuation devices to position sensors orthogonally and densely around vessels, optimizing sensor placement based on wave propagation characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pressure vessels are subjected to cyclic and static fatigue loading, then their structural integrity degrades over time, but the remaining life cannot be accurately determined due to uncertainties in cycle counting and stress analysis
Solution Approach 1:
The patent replaces mechanical cycle counting and stress analysis methods with acoustic emission sensing. MAE sensors detect acoustic signals generated by fatigue damage mechanisms (crack initiation, propagation, fiber fracture, matrix cracking) directly, providing real-time information about vessel integrity without relying on uncertain mathematical projections of fatigue life.
Solution Approach 2:
The patent introduces acoustic emission sensors as an intermediary between the pressure vessel structure and the assessment system. These sensors detect and transmit acoustic signals from fatigue damage mechanisms, enabling indirect measurement of structural integrity and remaining life with greater accuracy than direct mechanical testing or computational projection.
2Measurement precision
If MAE sensors are used to assess pressure vessel integrity, then measurement precision improves, but device complexity increases due to multiple sensors and rail assemblies required for comprehensive coverage
Solution Approach 1:
The patent divides the sensor mounting system into modular components: multiple MAE sensors distributed along the vessel length, rail assemblies with rollers for positioning, and actuation devices for sensor activation. This segmentation allows comprehensive coverage of the vessel surface while maintaining manageable system complexity through standardized modular units.
Solution Approach 2:
The patent transitions from single-point sensor measurement to distributed multi-dimensional sensing. By arranging MAE sensors along the vessel surface in multiple locations and orientations, the system achieves comprehensive spatial coverage of fatigue damage mechanisms, enhancing measurement precision through multi-point detection.
3Measurement precision
If pressure vessels are tested in laboratory settings, then measurement precision is improved through controlled conditions, but productivity decreases due to removal from service and limited field assessment capability
Solution Approach 1:
The patent designs the MAE sensor system to be universally applicable to pressure vessels in various service conditions. The sensors and rail assemblies can be deployed in-field on vessels operating under different pressure ranges and cycle conditions, providing both controlled measurement capability and field assessment functionality without requiring vessel removal from service.
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
Enables efficient, in-field assessment of pressure vessel integrity and remaining life, enhancing signal sensitivity and coverage, and reducing uncertainties in fatigue life calculations.
Implementation Method 1
The first roller is attached to the first elongated frame member and is configured to contact and roll upon a first surface of one of the first, second, third and fourth vessels
Implementation Method 2
A sensor mounting system for pressure vessels that allows in-field testing using phased array Modal Acoustic Emission (PA-MAE) sensors
Data Source
AI summary
A sensor mounting assembly is configured for use with a vessel arrangement including at least four vessels. The assembly includes first and second elongated frame members, first and second rollers, and first and second sensors. The first sensor is attached to the first elongated frame member and is configured to contact the surface of the first vessel upon actuation in a first direction. The second sensor is attached to the second elongated frame member and is configured to contact the surface of the second vessel upon actuation in a second direction that is substantially orthogonal to the first direction. This disclosure also describes a method of mounting at least six sensors for use with a vessel arrangement including at least four vessels, the vessel arrangement disposed in a container in a two-by-two stacked configuration having a central space.