Tube Expansion Sensor for Automatic Stop Control
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Solution Overview
Problem
Conventional systems for expanding heat exchanger tubes lack an effective method to automatically stop the expansion process once the desired expanded state is reached, relying on displacement sensors and pressure controls which can be complex and prone to errors.
Innovation Solution
A dimension sensor system that includes a body member with detector elements, which forms an electrical circuit that changes from open to closed when the tube reaches the desired expanded state, automatically shutting off the pumping device to terminate expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional displacement sensors and compressor control systems are used to monitor tube expansion, then expansion progress can be measured, but the system becomes complex and prone to errors
Solution Approach 1:
The patent replaces complex mechanical displacement sensors and compressor control systems with a simple electrical circuit-based detection system. The detector element directly contacts the tube to sense expansion, and the electrical circuit automatically controls the pumping device, eliminating the need for complex mechanical measurement and control components.
Solution Approach 2:
The detection system is self-regulating through the electrical circuit. When the detector element contacts the expanded tube, the circuit automatically opens to shut off the pumping device, requiring no external control system or manual intervention. The system serves itself by using the tube's own expansion to trigger the shutdown.
2Manufacturing precision
If expansion is stopped manually or with complex control systems, then over-expansion can be prevented, but manufacturing efficiency is reduced
Solution Approach 1:
The patent implements immediate feedback control where the detector element continuously monitors tube expansion and directly controls the pumping device through the electrical circuit. When the desired expansion is reached, the circuit automatically opens to stop expansion, providing real-time feedback without delay or complex processing.
Solution Approach 2:
The patent replaces manual or complex automated control systems with a simple electrical circuit that directly responds to tube expansion. This substitution maintains precise expansion termination while significantly improving manufacturing efficiency by eliminating complex control mechanisms.
3Device complexity
If a simple detector element is used to sense tube expansion, then device complexity is reduced, but reliable detection of the expanded state may be insufficient
Solution Approach 1:
The patent uses the electrical circuit as an intermediary between the simple detector element and the pumping device. The detector element's contact with the tube triggers the circuit, which then reliably controls the pumping device shutdown. This intermediary ensures that even a simple detector can reliably control the expansion process.
Solution Approach 2:
The patent replaces complex mechanical detection systems with a simple electrical circuit-based detection system. The electrical circuit provides reliable signal transmission and control, ensuring that the simple detector element can effectively and reliably control the expansion termination.
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
Ensures precise and automatic termination of the tube expansion process, preventing over-expansion and ensuring consistent, secure contact with plate fins, thereby improving the manufacturing efficiency of heat exchangers.
Implementation Method 1
the detector element is connected to the body member and has a detector portion extending into the opening... When the tube is received in the opening, the detector portion is initially disposed apart from the tube
Implementation Method 2
The tube is expanded from a pre-expanded state to the desired expanded state by a fluid pressurized by a pumping device
Data Source
AI summary
A dimension sensor is used in conjunction with a tube and includes a body member and at least one detector element. The body member has an inner surface defining an opening sized to receive the tube. The at least one detector element is connected to the body member and has a detector portion extending into the opening. When the tube is received in the opening, the detector portion is initially disposed apart from the tube. A method using the dimension sensor stops expansion of the tube expanding from a pre-expanded state to a desired expanded state. A pumping device is actuated to pressurize a fluid by an amount sufficient to cause the tube to expand from the pre-expanded state to the desired expanded state. When the tube expands to the desired expanded state, the pumping device deactivates thereby stopping expansion of the tube at the desired expanded state.