Wireless Sensor Fittings for Fluid Network Predictive Maintenance

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Solution Overview

Problem

Fluid delivery and distribution systems lack system-wide intelligence due to the high cost of replacing unintelligent components with intelligent ones, leading to insufficient monitoring and predictive maintenance capabilities.

Innovation Solution

A hybrid wireless sensor network architecture that integrates intelligent fittings capable of measuring fluid characteristics and communicating data wirelessly to a controller, converting existing unintelligent components into intelligent ones at a lower cost, and supplementing data from intelligent components, while using a digital twin to model the system's topology.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If existing unintelligent components are replaced with intelligent components, then system-wide monitoring and predictive maintenance capabilities are improved, but system cost increases significantly

Engineering Contradiction:

Improvesystem-wide monitoring capabilityVSAvoidsystem cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The system is segmented into intelligent components (with embedded sensors and communication capabilities) and unintelligent components (standard components without intelligence). This segmentation allows selective deployment of intelligence only where critical for system-wide monitoring, rather than requiring all components to be intelligent, thereby reducing overall system cost while maintaining monitoring capability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A wireless communication network acts as an intermediary between intelligent and unintelligent components. The intelligent components communicate system state information wirelessly to a central controller, enabling monitoring of the entire system without requiring direct integration or replacement of all components with intelligent ones.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If intelligent components are deployed system-wide, then predictive maintenance and diagnostic capabilities are enhanced, but device complexity increases

Engineering Contradiction:

Improvepredictive maintenance capabilityVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The intelligent components are designed with multi-functionality, serving both as fluid distribution elements and as sensor nodes with wireless communication capabilities. This consolidation of functions reduces the number of separate devices needed and simplifies system architecture compared to adding dedicated monitoring equipment to each component.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system implements feedback loops where intelligent components continuously monitor fluid characteristics and component status, transmit this data wirelessly to a central controller, and enable real-time adjustments and predictive maintenance decisions. This automated feedback mechanism enhances predictive maintenance capability while managing complexity through standardized communication protocols.

Inventive Principle:

Principle #23Feedback

3Measurement precision

If more sensors and instrumentation are added to components, then measurement precision and system control are improved, but manufacturing cost increases

Engineering Contradiction:

Improvefluid characteristic measurementVSAvoidcomponent cost

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

Multiple functions are merged into the intelligent fittings: fluid distribution, pressure sensing, temperature sensing, flow measurement, and wireless communication. By combining these functions into a single integrated component rather than adding separate sensors and communication devices to each component, manufacturing cost is reduced while maintaining measurement precision.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent uses a digital twin approach where a virtual replica of the physical fluid distribution system is created and maintained. This digital copy receives data from intelligent components and allows for simulation, analysis, and predictive maintenance without requiring additional physical sensors or instrumentation in the actual system.

Inventive Principle:

Principle #26Copying

Data Source

PatentEP3577883B1Hybrid wireless sensor network architecture for fluid delivery and distribution systems

Publication Date: 2023.10.11 DANFOSS POWER SOLUTIONS II TECH AS

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AI summary

The present disclosure describes a hybrid, wireless sensor network architecture for monitoring, operating, controlling, or maintaining a fluid delivery and distribution system. The architecture includes intelligent fittings locatable at almost any location within the system and that are configured with sensor modules to make measurements of characteristics of a fluid passing therethrough or of component parameters, and with wireless communication modules to wireless communicate the measurements. The intelligent fittings may be used, via strategic location, to convert unintelligent components of the system into intelligent components at a cost lower than that required to replace the unintelligent components with intelligent components. The intelligent fittings may also replace unintelligent fittings to provide supplemental data corresponding to fluid characteristics at desired locations of a fluid delivery and distribution system. The architecture further includes a digital twin of a hybrid, wireless sensor network that may downloaded to controllers for use.