Subsea Sensor Module Shrink-Fit Flange Design
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Solution Overview
Problem
Conventional subsea sensor modules are large, heavy, and expensive due to strict regulatory requirements, limiting the use of larger nuts and bolts for fixing, which can lead to space constraints and reduced structural integrity under high pressures.
Innovation Solution
A subsea sensor module design featuring a sensor housing and flange formed from different materials, with a shrink-fit assembly allowing for increased space for larger nuts and bolts, enabling operation at high pressures while reducing size, weight, and cost, and incorporating dual functionality for pressure and temperature sensing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the housing and flange are made from a single piece of material, then structural integrity is improved, but the available space for fixing the flange is reduced and cost increases
Solution Approach 1:
The housing and flange are divided into two separate components made from different materials. The housing is made from a first material optimized for sensor protection, while the flange is made from a second material optimized for joining and fixing. This segmentation allows each component to be independently optimized for its specific function, increasing the available space for fixing while maintaining structural integrity through the shrink-fit connection.
2Ease of manufacture
If the housing and flange are made from different materials, then cost is reduced and customization is improved, but manufacturing complexity increases
Solution Approach 1:
The shrink-fit connection utilizes thermal expansion and contraction parameters to join the housing and flange. By heating the flange or cooling the housing, the dimensions of the components change temporarily to enable assembly, then return to their original dimensions to create a tight interference fit. This parameter change approach simplifies the joining process compared to traditional welding or threading, reducing manufacturing complexity while enabling the use of different materials.
Solution Approach 2:
The assembly combines two different materials in a composite structure, where each material is selected for its optimal properties for the specific application requirements. This allows customization of each component based on functional needs while reducing overall cost by not requiring expensive materials throughout the entire assembly.
3Ease of operation
If larger nuts and bolts are used for fixing, then ease of operation is improved, but space requirements increase
Solution Approach 1:
The flange design extends the fixing surface in the radial dimension, providing adequate space for larger nuts and bolts without increasing the axial length of the assembly. This dimensional approach allows standard large-format fasteners to be used for easier operation and maintenance while keeping the overall package size compact.
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 design allows for reliable operation at up to 15K PSI with reduced size and weight, accommodating larger nuts and bolts, enhancing structural integrity and customization options while meeting stringent subsea standards.
Implementation Method 1
heating the flange or cooling the sensor housing, such that the inner profile of the flange increases, or the outer profile of the housing decreases, sufficiently to enable the flange to be mounted radially outwardly of the sensor housing
Implementation Method 2
cooling the flange, or heating the sensor housing, sufficiently to bring the housing flange shoulder and corresponding module flange shoulder into contact by shrink fitting
Data Source
AI summary
A subsea sensor module includes a sensor housing having a first section, a second section and a third section, each section having an outer profile and a module flange having an inner profile. An outer surface of the flange is substantially perpendicular to an outer surface of the housing in the first section. The housing outer profile and flange inner profile are substantially the same along the second section of the housing. A shoulder is formed in the housing outer profile in the third section by a transition of the diameter of the outer profile from a smaller to a larger diameter. The flange has a corresponding shoulder in the flange inner profile; wherein the flange is shrink fit mounted radially outwardly of the sensor housing second section such that the shoulders are in contact.