Robotic Sniffer Leak Detection for Heat Exchangers
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Solution Overview
Problem
Current leak detection methods for heat exchange devices are time-consuming and prone to errors due to human factors, such as omitting test areas or not moving the sniffer probe sufficiently close to a test area.
Innovation Solution
A robot-guided leak detection system that uses a 3D sensor to automate the movement of a sniffer probe to predetermined test locations, records measurement signals and positions, and correlates these data to identify potential leaks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual sniffer probe inspection is used, then the operator can visually identify test areas and perform leak detection, but the process is time-consuming and prone to human errors such as omitting test areas
Solution Approach 1:
The patent replaces the manual mechanical inspection process with an automated robotic system. The robot arm mechanically positions the sniffer probe according to pre-stored 3D coordinate data of test areas, eliminating human visual identification and manual positioning. This substitution ensures consistent, accurate positioning at all test areas while reducing inspection time through automated, high-speed movement and measurement.
2Ease of operation
If manual probe movement is used, then the operator can subjectively assess test areas, but certain test areas may be omitted or skipped due to human factors
Solution Approach 1:
The system enables the robot to autonomously perform the complete leak detection process without human intervention during execution. The robot automatically positions the probe at each test area coordinate, activates the sniffer measurement, and records results. The system self-manages the entire inspection sequence based on pre-programmed 3D coordinates, ensuring all test areas are covered without omission while requiring minimal human input for setup and operation.
3Productivity
If automated robot-guided probe movement is implemented, then leak detection becomes faster and more reliable, but the system complexity increases due to integration of robot, 3D sensor, and measurement system
Solution Approach 1:
The patent integrates multiple independent systems into a unified automated inspection platform. The robot arm, 3D sensor for coordinate capture, sniffer probe for gas detection, and control system are merged into a coordinated system that operates automatically. The 3D sensor data is stored and used by the robot for precise positioning, while the sniffer probe measurements are automatically recorded and evaluated, creating a streamlined integrated process that improves productivity despite the increased complexity of system integration.
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 system enables fully automated and reliable leak detection, reducing human error and increasing efficiency by accurately identifying leaks in heat exchange devices.
Implementation Method 1
a test gas detector in the base unit... configured, for example, as a mass spectrometer
Data Source
Figure 1
AI summary
The invention relates to an automated leak detection method using a robotic gas leak detector (56), characterised by the steps of: a) moving the probe tip (25) of a probe (22) guided by a robot (32) to a test site (20) to be examined, using a robot (32); b) recording a measurement signal from gas recorded by the probe tip (25) by means of a gas detector (24); c) detecting at least one first measurement value of the measurement signal at at least one first measurement time; d) detecting the first measurement time and assigning the first measurement time to the first measurement value; e) detecting and assigning a first measurement position of the probe (22) corresponding to the first measurement time; f) repeating steps a) - e) for at least one subsequent second measurement time; and g) correlating the measurement values with each of the measurement positions of the probe (22) in order to be able to use the measurement values to assess at which measurement position an extreme value of the measurement signal, which could indicate a possible leak in the test object, was detected.