Steam Trap Acoustic Sensing for Safer Real-Time Monitoring

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Solution Overview

Problem

Manual monitoring of steam and hot water systems is time-consuming, unreliable, and poses safety risks, lacking real-time data and requiring scheduled inspections to detect potential issues before they cause damage or danger.

Innovation Solution

A system comprising a central monitor, handheld devices, and wands with acoustic and thermal sensors for real-time monitoring of steam traps, allowing for remote data collection and reporting, and automatic detection of operational parameters and anomalies.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual inspection is used to monitor steam and hot water systems, then human intervention can detect potential issues, but the process is time-consuming and does not provide real-time information

Engineering Contradiction:

Improvedetection reliabilityVSAvoidinspection time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent replaces manual mechanical inspection with an automated electronic monitoring system that uses acoustic sensors to detect steam trap operations and thermal sensors to measure temperatures, eliminating the need for human intervention while providing continuous real-time data

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The monitoring system enables the steam and hot water system to self-monitor its own performance through automated sensors and processors that continuously collect, analyze, and report operational data without external human assistance

Inventive Principle:

Principle #25Self-service

2Reliability

If manual monitoring is performed to identify system issues, then potential problems can be detected, but the process poses safety risks to personnel

Engineering Contradiction:

Improveissue detection capabilityVSAvoidsafety risks

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces manual physical inspection with remote automated monitoring using acoustic and thermal sensors that can detect system anomalies without personnel needing to physically access potentially dangerous steam and hot water equipment

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces sensors and electronic intermediaries that act as mediators between the monitoring system and the steam/hot water system, allowing data collection without direct human contact with hazardous components

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If scheduled routine inspections are conducted to prevent serious damage, then potential problems can be caught early, but the process is not fully reliable and requires human intervention

Engineering Contradiction:

Improveproblem prevention capabilityVSAvoidautomation level

Core Design Contradiction:

ReliabilityVSExtent of automation

Solution Approach 1:

The monitoring system enables the steam and hot water system to self-monitor continuously through automated sensors and processors that collect, analyze, and report operational data without external human assistance, eliminating the need for scheduled manual inspections

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent implements continuous real-time monitoring that operates without interruption, constantly collecting and analyzing system data to detect issues as they develop, rather than relying on periodic discrete inspection events

Inventive Principle:

Principle #20Continuity of useful action

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 real-time monitoring and reporting of steam and hot water system components, reducing the risk of human error and improving safety by providing immediate feedback on system performance and potential issues.

Implementation Method 1

a first acoustic element located adjacent to the proximal end of the probe tip, a second acoustic element spaced from the first acoustic element... to test the steam trap acoustically

Methodology Applied

Scientific EffectAcoustic conduction: Acoustics

Implementation Method 2

a thermal sensor to test the steam trap thermally

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS11255823B2Steam/hot water device monitoring

Publication Date: 2022.02.22 ARMSTRONG INTERNATIONAL INC

AI summary

Systems and methods for testing steam traps or other similar devices in a hot water or steam system are described. A tester includes a wand that is handheld that can communicate with a handheld electronic device which in turn can communicate with a central monitor for storing and compiling readings as historical profile data. The wand includes a probe to physically contact the device to acoustically sense the performance of the device. The probe includes a probe tip and a stack of acoustic elements, an electrode, a stack mass, and a head to covert the acoustic signal into an electrical signal. The handheld device includes circuitry to process the information, interact with the user, and transmit information to and from the handheld electronic device and/or the central monitor.