Corrugated Tube Sensor Chains for Accumulated Damage Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing monitoring systems for corrugated flexible tubes in transfer systems fail to detect load peaks and accumulated damages, leading to premature replacement and waste, while not accounting for actual wear and tear, thus increasing maintenance costs and safety risks.
Innovation Solution
A monitoring system with sensor chains along the corrugated tube to measure bending and strain, connected to a signal processing unit that determines accumulated damages and issues warnings when thresholds are exceeded, enabling a flexible replacement schedule.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rigid replacement schedule is applied, then safety risks are reduced, but maintenance costs increase and tubes are replaced prematurely
Solution Approach 1:
The monitoring system continuously measures bending and strain of the corrugated tube using sensor chains, feeds this data to a signal processing unit that calculates accumulated damages, and provides feedback to determine optimal replacement timing. This closed-loop feedback mechanism replaces tubes based on actual condition rather than fixed schedules, preventing premature replacement while maintaining safety.
Solution Approach 2:
The corrugated tube effectively monitors its own condition through integrated sensor chains that measure its bending and strain. The tube's own operational data is used to determine when it should be replaced, eliminating the need for external inspection and enabling condition-based maintenance that reduces costs while ensuring safety.
2Reliability
If a rigid replacement schedule is applied, then safety risks are reduced, but tube lifetime is reduced
Solution Approach 1:
The system uses continuous feedback from sensor chains measuring bending and strain to calculate accumulated damages in real-time. This enables extension of tube lifetime by keeping them in service until actual damage thresholds are reached, rather than replacing them according to conservative fixed schedules, thus maximizing utilization without compromising safety.
Solution Approach 2:
The replacement schedule transitions from a static, predetermined time-based approach to a dynamic condition-based approach. The system continuously adapts the replacement decision based on real-time measurements of bending and strain, allowing the tube to operate as long as its actual condition permits, thereby extending useful lifetime while maintaining safety.
3Measurement precision
If sensor chains are installed to monitor bending and strain, then accumulated damages can be detected, but device complexity increases
Solution Approach 1:
The monitoring system is segmented into distinct functional modules: sensor chains for measurement, signal processing unit for data analysis, and a replacement decision system. This segmentation allows each component to be optimized independently and simplifies installation and maintenance, reducing overall system complexity while maintaining high measurement precision for damage detection.
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 a flexible replacement schedule based on actual tube condition, reducing maintenance costs and extending the useful life of corrugated tubes by accurately detecting damage accumulation.
Implementation Method 1
The sensor chains are configured to measure bending and/or strain exerted on the corrugated tube
Data Source
Figure 1~3(c)
AI summary
A monitoring system (100) and a method for detecting bending and/or strain of a corrugated tube (101) are suggested. The system comprises at least two sensor chains (103) extending along a longitudinal direction of the corrugated tube at different circumferential positions. The sensor chains are configured to measure bending and/or strain exerted on the corrugated tube. The sensor chains are connected to a signal processing unit (102) that is configured to process output signals of the sensor chains for determining accumulated damages.