Wire Rope Conductor for Guided Wave Radar with Crimped Spacer Retainers
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Solution Overview
Problem
Existing guided wave radar level transmitters with coaxial probes face challenges such as brittle ceramic spacers that are prone to breakage during assembly, complex and costly construction, and inability to trim the probe length in the field, especially in high-temperature and pressure applications.
Innovation Solution
A coaxial guided wave radar apparatus featuring a wire rope central conductor with crimped retainers to secure ceramic spacers at predetermined lengths, a tensioner to maintain spacing from the outer conductor, and a flexible design allowing field trimming and adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If brittle ceramic spacers are used in high-temperature and pressure coaxial probes, then the probe can withstand harsh environmental conditions, but the spacers are prone to breakage during assembly and the construction becomes complex and costly
Solution Approach 1:
The probe is divided into modular sections with ceramic spacers positioned at predetermined lengths along the central conductor. Each spacer is secured by retainers that can be independently installed, allowing分段 assembly that reduces complexity while maintaining high-temperature resistance
Solution Approach 2:
Ceramic spacers are pre-positioned and secured with retainers along the central conductor at predetermined intervals before final assembly. This preliminary positioning ensures proper spacing is established early in the assembly process, preventing misalignment and reducing on-site assembly difficulty
2Strength
If a rigid rod central conductor with ceramic spacers is used, then the probe maintains structural integrity, but the probe length cannot be trimmed in the field and assembly becomes more complex
Solution Approach 1:
The central conductor is designed as a flexible wire rope rather than a rigid rod, allowing the probe length to be trimmed and adjusted in the field. The wire rope maintains sufficient structural integrity through its construction while enabling dynamic adaptation to different installation requirements
Solution Approach 2:
Ceramic spacers are positioned only at specific predetermined locations along the central conductor where they are needed for electrical insulation and spacing, rather than continuously. This localized placement reduces material usage and assembly complexity while maintaining structural integrity at critical points
3Ease of manufacture
If ceramic spacers are positioned without retainers, then the construction is simpler, but the spacers cannot be securely held in place at predetermined lengths
Solution Approach 1:
Metal retainers are introduced as intermediary components that secure the ceramic spacers to the central conductor. These retainers are crimped onto the wire rope at predetermined locations and provide reliable anchoring points for the spacers, ensuring they remain in place during installation and operation while adding minimal complexity to the overall construction
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
This solution simplifies assembly, reduces costs, enhances durability by minimizing spacer breakage, and allows for in-field length adjustments, making the system easier to assemble and more cost-effective while maintaining measurement accuracy.
Implementation Method 1
one or more spacers can be positioned and held in place about the central conductor at predetermined lengths along the central conductor, wherein each spacer is positioned and held in place along the central conductor by one or more respective retainers that are crimped to the central conductor
Implementation Method 2
A tensioner can be attached to the end of the wire rope of the central conductor. The tensioner allows for a proper tension to be applied to maintain a spacing of the wire rope from an outer conductor
Implementation Method 3
GWR uses time domain reflectometry to measure the distance to the product. In GWR measurement systems, a waveguide is used to direct a short (e.g., ~1 ns) EM pulse towards the surface of the medium in the tank
Data Source
AI summary
A coaxial guided wave radar apparatus includes a central conductor configured as a wire rope. One or more spacers can be positioned and held in place about the central conductor at predetermined lengths along the central conductor, wherein each spacer is positioned and held in place along the central conductor by one or more respective retainers that are crimped to the central conductor. A tensioner can be attached to the end of the wire rope of the central conductor. The tensioner allows for a proper tension to be applied to maintain a spacing of the wire rope from an outer conductor.