Wear Detection Pipe With Flush Wire Ends
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Solution Overview
Problem
Existing wear detection systems for conduits transporting abrasive materials cannot be easily recut to length without compromising the electrical connection of the conduit wires to the detection system, limiting adaptability and ease of installation.
Innovation Solution
The conduit is designed with pairs of electrically conductive wires arranged in helical windings, with ends that remain flush on the end faces, allowing interchangeable positioning of connection and bridge-forming means at either end, enabling recutting without disrupting electrical connectivity, and utilizing annular seals and conductive tips for secure connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the conduit is recut to length, then the adaptability and ease of installation are improved, but the electrical connection of the conduit wires to the detection system is compromised
Solution Approach 1:
The conduit system is segmented into modular components with standardized wire exit positions. The wires are arranged in helical windings that maintain consistent spacing and positioning relative to the conduit end faces, allowing the conduit to be divided into different lengths while preserving electrical connection integrity through standardized connector interfaces.
Solution Approach 2:
The conduit design incorporates universal wire routing features where pairs of wires at each detection level are positioned to exit at standardized locations on the end faces. This universal positioning allows the same connector design to be used regardless of conduit length, enabling the system to adapt to different installation requirements while maintaining reliable electrical connections.
2Ease of operation
If the wires extend projecting from the conduit, then the electrical connection to the detection system is simplified, but the ability to recut the conduit is lost
Solution Approach 1:
The wires are pre-positioned in helical windings within the conduit wall during manufacturing, with their ends positioned to exit flush with predetermined locations on the end faces. This preliminary positioning ensures that when the conduit is cut to the desired length, the wires will automatically be at the correct position for connection, eliminating the need for post-installation adjustments while maintaining ease of connection.
Solution Approach 2:
Instead of having wires extend beyond the conduit end and then trimming them, the invention inverts the approach by positioning wire ends to exit flush with the conduit end face after cutting. This inversion allows the conduit to be cut first to the required length, and then the wires naturally present themselves at the correct position for connection, combining adaptability with ease of operation.
3Measurement precision
If the conduit is designed with fixed wire positions for detection, then the wear detection precision is improved, but the manufacturing flexibility is reduced
Solution Approach 1:
The wire positions are defined by parameters related to the helical winding geometry (pitch, diameter, number of turns) rather than fixed absolute positions. This allows the same detection precision to be achieved across conduits of different lengths by adjusting the winding parameters during manufacturing, maintaining measurement precision while preserving manufacturing flexibility.
Solution Approach 2:
The helical winding structure provides local quality control where the wire spacing and positioning are optimized for wear detection at each specific location along the conduit. Each section of the conduit maintains the precise geometric relationships needed for accurate detection, while the overall structure remains flexible to manufacturing variations and different conduit lengths.
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
Facilitates easy recutting and installation of conduits of varying lengths while maintaining reliable electrical connections, reducing the risk of errors and simplifying the manufacturing process, allowing for effective wear detection at multiple levels along the conduit radius.
Implementation Method 1
each pair of wires (5, 6) being electrically conductive
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
The invention relates to an assembly (2) comprising a pipe (3) provided with a pair of electrically conductive wires (5, 6) in which wear is to be detected and a connector (4) for connecting the pipe (3) to a wear-detection system (9). The wires (5, 6) of the pair of electrically insulated wires extend in the body of the pipe (3) with a first end, referred to as first end, flush with one (31) of the surfaces (31, 32) of the end of the pipe (3) and a second end flush with the other one (32) of the end surfaces (31, 32) of the pipe (3), and the connector (4) for said pair of wires (5, 6) comprises means (7) for forming an electric bridge between the first two ends of the wires (5; 6) of said pair of wires and means (8) for electric connection of the second ends (52, 62) of the wires (5, 6) of said pair of wires to the detection system (9) configured to detect a change in at least one conductive characteristic of said electric circuit formed by the wires (5, 6) of the pair of wires.