Embedded Sensor Hose Wall for Precise Wear Point Detection
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Solution Overview
Problem
Existing hoses used for conveying liquids with solids experience significant wear and abrasion, leading to potential tears and pressure losses, which are difficult to detect efficiently, especially when multiple hoses are connected, causing interruptions in liquid delivery.
Innovation Solution
A hose design featuring embedded sensor lines in multiple layers of the tubular hose wall, with an evaluation unit to detect electrical conductivity and continuity, allowing for precise and robust detection of wear points, even under mechanical stress, enabling timely maintenance and preventing hose failure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection methods are used to detect wear, then wear detection is possible, but the inspection process is complex and expensive requiring interruption of fluid pumping, rinsing, and emptying
Solution Approach 1:
The patent replaces manual mechanical inspection with an automated sensor system. Electrical conductivity sensors embedded in the hose wall detect wear through changes in electrical properties, eliminating the need for manual interruption, rinsing, and visual inspection of the hose interior.
Solution Approach 2:
The hose performs self-diagnosis through embedded sensors that continuously monitor its own condition. The evaluation unit automatically detects wear based on electrical conductivity changes, allowing the system to monitor itself without external intervention or shutdown.
2Measurement precision
If transponders are embedded in the hose wall for wear detection, then wear can be detected, but the transponders are vulnerable to damage from bending and tensile stress
Solution Approach 1:
The patent uses sensor lines made from the same elastomeric base material as the hose wall, ensuring uniform mechanical properties. This homogeneity allows the sensors to withstand bending and tensile stress equally well as the hose itself, preventing differential damage.
Solution Approach 2:
The patent creates a composite structure where conductive elements are integrated within the elastomeric base material. The combination of elastomer and conductive material produces a sensor system that maintains flexibility and stress resistance while providing electrical conductivity for wear detection.
3Device complexity
If a single sensor line is used, then the structure is simple, but wear detection precision and radial position determination are insufficient
Solution Approach 1:
The patent divides the sensor system into multiple sensor lines positioned at different radial distances from the hose inner surface. This segmentation allows detection of wear at different stages and positions, enabling precise localization of wear points through pattern recognition across multiple sensor levels.
Solution Approach 2:
The patent adds a radial dimension to wear detection by positioning sensor lines at different radial distances. This creates a two-dimensional detection network (circumferential position plus radial depth) that precisely locates wear points and determines wear progression through the hose wall thickness.
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 hose design allows for early detection of wear and damage, reducing the risk of hose failure and pressure losses, ensuring continuous liquid delivery by providing a robust and efficient monitoring system for wear and tear.
Implementation Method 1
Each of the sensor lines (6) is electrically coupled to the evaluation unit (34) by an associated first end, directly or indirectly. Each of the sensor lines (6) is electrically coupled, directly or indirectly, to the evaluation unit (34) via an associated second end. The evaluation unit (34) is designed to detect the electrical conductivity and/or continuity of each of the sensor lines (6).
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The invention relates to a hose (2) with an elastomeric hose wall (4), an evaluation unit, and several first and second sensor lines (6a) distributed circumferentially and radially embedded in the base material (8) of the hose wall. The sensor lines (6a, 6b) are coupled directly or indirectly to the evaluation unit, the evaluation unit (34) being configured to detect the electrical conductivity and/or continuity of each of the sensor lines (6a, 6b) and to determine a circumferential and radial position of a wear point on the inside of the hose wall (4) based on the detected electrical conductivity and/or continuity of the sensor lines (6a, 6b).