Wireless Flange Tensioning Sensor with Hydraulic Clamping Module
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Solution Overview
Problem
Monitoring and adjusting flange connections with a large number of clamping elements is time-consuming due to the need for extensive cable connections for data acquisition in hazardous areas, such as chemical and nuclear power plants, where quick and accurate assembly is crucial.
Innovation Solution
A measuring device with a wireless bidirectional communication capability, integrated with a clamping module that uses hydraulic means for generating tensile force and includes a display unit for showing favorable or unfavorable changes in clamping element length, allowing remote-controlled adjustment and wireless transmission of measurement information to a signal receiver.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional measuring devices with cable connections are used for data acquisition, then measurement data can be acquired, but the process becomes time-consuming and complex due to extensive cable connections required in hazardous areas
Solution Approach 1:
The patent replaces the mechanical cable connection system with a wireless communication system. The measuring device transmits measurement information wirelessly to a signal receiver, eliminating the need for physical cable connections in hazardous areas. This substitution reduces setup time and complexity while maintaining measurement data acquisition capabilities.
Solution Approach 2:
The patent extracts the communication function from the physical cable connection system and implements it as a separate wireless transmission system. The electronic assembly in the measuring device handles wireless transmission independently, removing the burden of cable management from the overall system setup.
2Reliability
If multiple cable connections are laid for data acquisition from multiple clamping elements, then comprehensive monitoring is achieved, but the device complexity and setup effort increase significantly
Solution Approach 1:
The patent replaces the complex mechanical cable connection infrastructure with wireless communication. Each measuring device equipped with an electronic assembly can transmit data independently, eliminating the need for extensive cable routing and connection management while maintaining comprehensive monitoring of all clamping elements.
Solution Approach 2:
The patent divides the monitoring system into independent modular units. Each measuring device with its electronic assembly operates as a self-contained segment that can function independently, allowing for simplified deployment and reduced overall system complexity compared to a centralized cable-based architecture.
3Manufacturing precision
If manual adjustment of each clamping element is performed, then precise control is achieved, but the process requires significant time and effort especially in hazardous areas
Solution Approach 1:
The patent implements a feedback system where measuring devices continuously monitor clamping element status and transmit data wirelessly to a control system. This real-time feedback enables automated or semi-automated adjustment processes, allowing precise control of clamping force while significantly reducing manual intervention time and improving assembly productivity.
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 quick and accurate adjustment of flange connections with reduced setup time and effort, allowing a single person to efficiently manage multiple clamping elements in hazardous environments by providing real-time feedback on clamping force through visual and wireless communication.
Implementation Method 1
the measuring device contains at least one magnetization sensor and has a movable measuring sensor for detecting an elongation of the clamping element caused during clamping. Magnetizing material is located on the carrier element and has zones with different magnetization. By detecting the magnetization of these zones with the at least one magnetization sensor, it is possible to deduce the change in length of a corresponding clamping element.
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
The measuring device (38) has a sensor for the detection of a length change of a clamping element, where an electrical component of the sensor is electrically connected with an electric assembly for the wireless transmission of measurement information at a signal receiver (42). The electric assembly is received at a carrier (39). The electric assembly is designed for wireless bidirectional communication with a control computer (40). Independent claims are included for the following: (1) a clamping module with a unit; (2) a device with a supply line; and (3) a method for controlled clamping of a flange connection by multiple clamping elements.