Wireless Sensors for In-Situ Process Monitoring
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Solution Overview
Problem
Existing methods for monitoring fluids or gases in process applications, such as packed distillation columns, face challenges due to the difficulty in installing wired sensors, especially in harsh environments, and often provide measurements that are not representative of in-situ conditions, leading to inefficient process optimization and increased costs.
Innovation Solution
The implementation of wireless sensors that can transmit parameters like temperature, concentration, and liquid height within process equipment, allowing for real-time monitoring and control, even in locations where wired sensors are impractical, using RF signals that can traverse physical barriers and interference, and can be powered by batteries or RF energy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If wired fluid sensors are installed within process equipment to monitor fluids or gases, then measurement capability is improved, but installation difficulty and complexity increase significantly
Solution Approach 1:
The patent replaces wired mechanical sensor connections with wireless communication technology. Sensors equipped with wireless transmitters communicate process data through wireless signals, eliminating the need for physical wire leads running through harsh process environments. This substitution maintains measurement precision while dramatically reducing installation complexity and eliminating wiring-related safety hazards.
Solution Approach 2:
The patent extracts the wire leads from the sensor system, removing them entirely from the installation. By using wireless communication, the sensor can be installed at optimal measurement locations without requiring wire connections to distant control units, thereby simplifying installation and enabling monitoring in previously inaccessible locations.
2Measurement precision
If wired fluid sensors are installed at locations far from control units to optimize measurement, then measurement representativeness is improved, but wiring requirements and safety compliance difficulty increase
Solution Approach 1:
The patent replaces the mechanical wiring system with wireless communication infrastructure. Sensors located at optimal in-situ measurement points transmit data wirelessly to control units, eliminating the need to run wires through hazardous areas or comply with complex wiring codes. This maintains measurement accuracy while dramatically improving installation ease.
3Ease of manufacture
If bulk measurements are taken at input or output of process streams, then installation simplicity is improved, but measurement representativeness of in-situ conditions deteriorates
Solution Approach 1:
The patent uses wireless sensor technology to place measurement points directly within the process stream at critical in-situ locations. The wireless communication capability allows sensors to be positioned where they can directly measure local conditions without requiring wire connections, thereby achieving both installation ease and measurement representativeness simultaneously.
4Measurement precision
If multiple wireless sensors are deployed within process streams for comprehensive monitoring, then measurement coverage and accuracy are improved, but system complexity and power requirements increase
Solution Approach 1:
The patent implements periodic measurement and transmission cycles for wireless sensors. Sensors can remain in low-power sleep mode between measurements and only activate periodically to take measurements and transmit data. This periodic operation maintains comprehensive process monitoring capability while significantly reducing average power consumption compared to continuous operation.
Solution Approach 2:
The patent employs feedback mechanisms where sensors monitor their own power levels and adjust their measurement and transmission frequency accordingly. When power is abundant, sensors can operate more frequently for higher precision; when power is limited, they reduce activity to conserve energy. This feedback-based adaptation optimizes the balance between measurement precision and power consumption.
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 accurate, real-time monitoring and control of process conditions, improving efficiency and reducing costs by providing direct measurements from within the process stream, thus optimizing operations and reducing unnecessary power usage.
Implementation Method 1
wireless sensors that can transmit parameters like temperature, concentration, and liquid height within process equipment, allowing for real-time monitoring and control, even in locations where wired sensors are impractical, using RF signals that can traverse physical barriers and interference
Implementation Method 2
wireless sensors disposed within a fluid or gas process stream... sensing one or more parameters within the process stream using at least one of the wireless sensors
Data Source
AI summary
Monitoring systems and methods for monitoring one or more parameters within process equipment are disclosed. A monitoring system for wirelessly monitoring the process equipment can include a number of wireless sensors disposed within a fluid or gas process stream for monitoring various aspects of the fluid or gas medium such as temperature or pressure. Each of the wireless sensors can include a transmitter that can be used to wirelessly transmit sensor signals to a receiver in communication with a central monitoring unit. The wireless sensors can be placed directly within the fluid or gas medium, allowing accurate measurements to be taken within the process stream.