SENSOR QUICK-CONNECTION SYSTEM AND METHOD

A quick connect sensor coupling is described. The sensor coupling comprises a housing defining a first portion and a second portion; a sensor captured within the first portion; and a gripper stop comprising a taped surface and captured between the second portion and a pipe.

TECHNICAL FIELD

This disclosure relates to sensors in a utility system. More specifically, this disclosure relates to the rapid, repeatable, and secure coupling of a sensor, such as a hydrophone, into a utility system, such as a water utility.

BACKGROUND

A municipal utility system (e.g., a water system) can include various complex components designed to collect, treat, and distribute water to residences, businesses, and/or other facilities, e.g., within a city or town. The water, or other utility, typically must be sourced, cleaned, and distributed to each facility, usually through piping components. The quality and quantity of the source water can significantly impact the operation of the municipal water system, and regular inspections and maintenance of the system can ensure that the structure is safe and efficiently providing residents with potable drinking water. Since each component of the utility system plays a crucial role in delivering safe, reliable water supplies, the system should be carefully managed and maintained to protect public health, support economic activity, and/or safeguard the environment.

Sensors can be attached to the system. Methods of attachment and/or detachment of such sensors can damage the sensor and/or interfere with the utility services.

SUMMARY

In one aspect, disclosed is a sensor coupling comprising: a housing defining a first portion and a second portion, a sensor captured within the first portion, and a gripper stop comprising a taped surface and captured between the second portion and a pipe.

In a further aspect, disclosed is a quick-connect sensor coupling comprising: a housing defining a first portion and a second portion defining an angled section, a hydrophone coupled to an electronic transmitting device and disposed within a cavity defined within the first portion, and a gripper stop comprising a tapered surface and captured between the angled section of the second portion.

In yet another aspect, disclosed is a sensor coupling comprising: a housing defining a first portion and a second portion defining an angled section, a sensor coupled to an electronic transmitting device and disposed within a cavity defined within the first portion, and a gripper stop comprising a tapered surface and captured between the angled section of the second portion and a pipe.

DETAILED DESCRIPTION

In one aspect, a quick-connect system for attaching a sensor and associated methods, systems, devices, and various apparatuses are disclosed herein. In one aspect, the quick-connect system can comprise a housing that orients the sensor in a fluid column and securely and quickly attaches the sensor without the need to rotate the sensor or housing.

One method of managing and inspecting a utility system involves a sensor, such as a microphone adapted to function in a liquid environment or a hydrophone. A sensor, such as a hydrophone, is a type of microphone specifically designed to be used underwater to record and/or listen to underwater sounds. Most sensors of this type, including hydrophones, utilize a piezoelectric transducer that generates an electric potential when subjected to a pressure change, such as an underwater sound wave. The sensor can detect leaks by listening to the escaping water or gas-generated sounds. In some examples, hydrophones can pinpoint the leak location along a pipeline, which can be especially useful for large-scale infrastructure like water mains or oil and gas pipelines, where leaks can lead to significant economic and environmental damage.

Sensors such as hydrophones can also be used to monitor the pipeline integrity. For example, sounds made by a pipeline can give clues to its overall health. Changes in the usual noise level can indicate a problem with the pipeline's operation, a blockage, and/or an improperly functioning valve. In some cases, hydrophones and other sensors can monitor pipelines for signs of tampering and/or unauthorized activity. For example, the hydrophone system could detect the sound of drilling or other mechanical work. Fluid sensors and hydrophones can benefit testing of plumbing systems or technologies, for example, to study the effects of different flow rates or pressures on the noise produced by a system.

One aspect of a quick-connect sensor coupling or sensor coupling assembly100is disclosed and described inFIG.1. The sensor coupling assembly100comprises a housing102comprising an upper or sensor portion104and a lower or gripping portion106. In various aspects, housing102can comprise any material. For example, housing102can comprise a material that is NSF61approved, or in other aspects can comprise any material as desired. For example, housing102can comprise steel, such as stainless steel, and brass, such as low lead brass. Sensor portion104houses and protects the sensing equipment (e.g., a hydrophone or other sensor302, as illustrated inFIG.3). Gripping portion106securely couples and/or fastens housing102to an end of a branch108, e.g., a pipe110extending upward from a fitting122. The fitting122can connect two pipes110that are configured for transferring water through the utility, shown inFIG.1extending laterally from fitting122. A third pipe110can comprise the branch108, shown extending upward from the fitting122inFIG.1, where the sensor302(e.g., a hydrophone) can attach. The branch108can be housed within a pit, which provides an underground cylindrical (or other shaped) housing for the hydrophone. In some aspects, the fitting122can also be located within the pit, and the laterally extending pipes110can extend out through sides of the pit. In other aspects, the fitting122can be below the pit and the branch108can extend upward from the fitting122into the pit. Various branches108, pipes110, fittings122and/or pits can be located in designated spots along the piping infrastructure to install monitoring hydrophones or other equipment along pipe110. For example, a T-fitting (e.g., fitting122) can be installed along the axis of pipe110to install a transverse branch108that can be coupled to housing102of a sensor coupling assembly100. In various aspects, fitting122can comprise another suitable fitting, such as and without limitation, a Y-fitting, an L-fitting, an X-fitting, a saddle fitting, or another suitable fitting for jointing branch108to pipes110.

In some aspects, an air release valve112can be secured to housing102. In various aspects, the air release valve112can be a ball valve, butterfly valve, or any other suitable valve. For example, the air release valve112can be threadedly coupled into a threaded portion114of housing102to secure the air release valve112. A threaded hole116in housing102comprises the threaded portion and couples to the air release valve112. When air release valve112is coupled to the threaded hole116, the air release valve extends radially from housing102. In some aspects, threaded hole116comprises threaded portion114to orient the air release valve112. In the illustrated aspect, the threaded hole116orients the air release valve112in a direction that is perpendicular to a central axis118of housing102such that the air release valve112extends radially outward from housing102. As illustrated, the hydrophone (or other sensors302ofFIG.3) is coupled to one end of housing102, and a pipe end120of sensor302(FIG.3) couples to branch108of pipe110at the opposite axial end of housing102, extending along the central axis118.

Air release valve112facilitates bleeding pipe110following installation of the sensor coupling assembly100, e.g., under pressure. For example, when a hydrophone or other sensor coupling assembly100is added to branch108, the pipe110can be charged and/or pressurized. The installation process may not ‘shut off’ the line and can proceed while the water line is pressurized. When the sensor coupling assembly100is coupled to pipe110, any air trapped inside branch108can be bled out of branch108and/or pipe110to enhance the reliability of the sensing equipment and reduce the maintenance and wear and tear on the sensing equipment. Air in the system can act as a dampener and reduce the magnitude of the noise carried in the water. Thus, the air is a dampener that can reduce the strength of the signal at the hydrophone or other transducer. Air release valve112facilitates the bleeding off of any trapped air in branch108and/or pipe110and enhances the functionality of the sensor coupling assembly100.

FIG.2shows an exploded view of the sensor coupling assembly100to illustrate the different features of the components described above in relation toFIG.1. Specifically, the threaded portion114of housing102is visible, as well as male threads202located on the air release valve112configured to threadedly secure the air release valve112into housing102. In various aspects, the sensing equipment is a transducer, such as a hydrophone, and without limitation, can comprise a pressure transducer, an electric transducer, and/or a vibratory transducer. The transducer (e.g., sensor302, illustrated inFIG.3) can have a relay structure, shown as an electric cable204, configured to relay information about the transducer to a computer or pressure monitoring system. Cable204can comprise one or more wires (e.g., multiple wires) and can provide power to the transducer and/or relay information about changes within the transducer, e.g., electronically to an electronically coupled computer structure or network.

An O-ring seal or seal206can be disposed within the coupling or gripping portion106of housing102. Seal206can be manufactured from an elastomer (e.g., rubber and/or moldable plastic) and can be captured between housing102and pipe110. In some aspects, a gap may exist between the gripping portion106and seal206. A gripping stop208can comprise a chamfer210on one end212and a circumferential lip214on an opposite end216. Various slots218can extend axially relative to pipe110through the gripping stop208and facilitate a sliding movement of the sensor coupling assembly100onto a pipe-end220of pipe110by allowing flexure of the portions of the gripping stop adjacent to slots218. Gripping stop208can also comprise compressible teeth222configured to securely grip into branch108, pipe110, and/or pipe end220and prevent housing102of sensor coupling assembly100from detaching from the designated branch108installed to monitor the pipe110. The slots218allow flexure that enables the teeth222to grip the branch108, pipe110, and/or pipe end220. Gripping stop208can be molded or manufactured from plastic (e.g., HDPE) and/or metal, such as various non-corrosive steels and/or brass, or another high-strength material that is capable of securely gripping an outer wall of branch108and/or pipe110with the teeth222of gripping stop208. In various aspects, the gripping stop208can securely grip the branch108and/or pipe110without penetrating and weakening the branch108and/or pipe110.

Gripping stop208and seal206are housed within the gripping portion106of housing102and captured between an upper or broader portion224and a lower or narrower portion226of the gripping portion106of housing102. In this way, both gripping stop208and seal206are captured within the gripping portion106of housing102, and as housing102(e.g., comprising sensor302shown inFIG.3) slides over pipe end220and onto branch108and/or pipe110, sensor302can slide within the branch108to measure and/or monitor the utility system. Any excess air trapped within housing102can be bled off. For example, if sensor302is a hydrophone and pipe110is carrying water, the hydrophone can be completely submerged in the water at the designated branch108of pipe110and can accurately monitor the system and detect changes in the sounds generated by the system to detect blockages, faulty valves, and/or potential leaks.

In some aspects, gripping stop208is a tapered piece, comprising a chamfer210and slots218. Slots218facilitate compressing the gripping stop208in order to facilitate placement of housing102over the gripping stop. The housing102and the gripping stop can be assembled by hand. Chamfer210can facilitate slipping housing102over the compressed gripping stop208. For example, housing102can be installed over gripping stop208by aligning and pushing housing102over the chamfer210to place housing102over the gripping stop208. Once housing102is installed over the gripping stop208, housing102can be pushed, then pulled, to secure the teeth222of gripping stop208against the outer wall of branch108and/or pipe110. For example, gripper stop208can comprise slots218extending axially parallel to the central axis that extends at least partially through the gripper stop208. Similarly, gripper stop208can comprise a chamfer210to facilitate translating the gripper stop208over housing102and/or within housing102.

In various aspects, this configuration enables the attachment of a sensor coupling assembly100comprising a sensor without rotation of housing102. Housing102can be slid onto pipe end220and fixed. In the aspect shown inFIG.2, the attachment can be semi-permanent. As used herein, a semi-permanent attachment is not permanent in the sense that it cannot possibly be removed, but the removal of a semi-permanent attachment is difficult without breaking the pipe and/or one or more portions or components of the sensor coupling assembly100. Therefore, in this aspect, once sensor coupling assembly100is attached to branch108at pipe end220in a semi-permanent fashion, it remains affixed until branch108, pipe110, and/or housing102is effectively removed entirely and replaced.

FIG.3shows a cross-section of the sensor coupling assembly100taken along line3-3ofFIG.1. The illustrated portions are shown in a simplified format. For example, the air release valve112and/or sensor302may not be solid pieces of material as illustrated and can have additional components which have not been illustrated. The cable204can be coupled to sensor302and can exchange information over a network. For example, sensor302(e.g., a hydrophone) can be coupled to an electronic transmitting device, such as cable204or a wireless network, to transmit electronic signals. Cable204securely passes through an orifice304of housing102to secure sensor302, e.g., in a water column in branch108that can be separated from the water flow through a central pipe110with a T-fitting (e.g., fitting122) to secure sensor302within branch108. In various aspects, potting or a gasket can be used to form a seal and secure sensor302within branch108. Sensor302and/or cable204can be securely fastened within sensor portion104of housing102with a sealing compound306, e.g., a potting compound or other molding that seals the sensor302and housing102interface. As shown, sensor302extends into a housing cavity308that can be within the water column, but sensor302does not extend all the way into branch108of pipe110. In this way, sensor302can be protected from the flow, debris, or other obstructions within pipe110to protect the sensor302. In various aspects, sensor302can be a hydrophone, a water quality sensor, a pressure sensor, a velocity sensor, etc. The sensor coupling assembly100comprises a housing102configured to quickly connect the sensor302to the water column in a branch108of the pipe110. The connection of sensor302in branch108can be reliable and secure enough that sensor302can provide accurate and repeatable data collection, e.g., following a calibration process.

In various aspects, a diameter310of transverse pipe110to form branch108can be less than 1 inch, such that a maximum diameter312of housing102at the gripping portion106can be less than 1.5 inches. More specifically, the maximum diameter of housing102at the gripping portion106can be, for example, and without limitation, less than 1.25 inches, 1 inch, 0.75 inches, or 0.5 inches, such that installation of housing102in narrow locations is feasible, even without a screwing or other transverse or rotational motion of the sensor coupling assembly100.

The narrow profile of housing102means that the sensor coupling assembly100can be affixed to a broader variety of branches108and/or pipes110and can enhance the overall system reliability to detect and locate leaks or other problems within the piping system. In some aspects, the maximum diameter312of housing102at the gripping portion106can be, for example, and without limitation, less than 25%, 20%, 15%, 10%, or 5% greater than the diameter310of the branch108. In various aspects, the maximum outer diameter312(e.g., of a portion of housing102) is less than, for example, and without limitation, 25% greater than an outer diameter of pipe110. Since the sensor coupling assembly100slides axially over the transverse pipe110to form branch108, the narrow cross-section at the maximum diameter312facilitates the secure attachment of sensors302where they may have been impossible with a more conventional, e.g., threaded assembly.

As illustrated inFIG.3, when housing102is pressed in a downward direction314, gripping stop208can slide in an upward direction316(e.g., opposite the downward direction314) into a pocket318of the gripping portion106of housing102. When gripping stop208compresses the seal206, the pocket318is reduced, and the seal206can be compressed to form a fluid-tight sealing boundary around pipe end220. If housing102is pulled in the upward direction316, e.g., to remove housing102from the pipe end220, angled sections320of the gripping portion106compress the gripping stop208. The taper on the gripping stop208interacts with the angled sections320to prevent removing housing102from the pipe end220. The greater the force in the upward direction316, the greater the gripping stop208secures housing102to the pipe end220by pushing the teeth222to further increase contact pressure on pipe110to create a secure connection for sensor302within the water column of branch108.

FIGS.4-6show another aspect of a sensor coupling assembly100. The sensor coupling assembly100shown inFIG.4is the same as illustrated inFIGS.1-3, except the sensor coupling assembly100inFIG.4further comprises a gripper flange402inserted within the angled sections320of the gripping portion106. Accordingly, all the description ofFIGS.1-3applies equally to the description ofFIGS.4-6, andFIGS.4-6further comprise structures and features that enable the removal and replacement of the sensor coupling assembly100.FIGS.1-3describe an assembly that has a semi-permanent attachment and cannot be easily removed without replacing branch108, pipe110, and/or sensor302.FIGS.4-6describe a removable attachment where the sensor coupling assembly100can be removed and replaced from one branch108to another without replacement of the branch108, pipe110, or sensor302.

ConcerningFIGS.4-6, the sensor coupling assembly100comprises housing102, defining upper/sensor portion104and lower/gripping portion106. Housing102can be manufactured from any suitable material, including NSF61approved materials. In aspects, housing102can comprise steel (e.g., stainless steel) and/or brass (e.g., low lead brass). Sensor portion104houses and protects the sensing equipment, e.g., sensor302,FIG.3. Gripping portion106securely couples and/or fastens housing102to an end of a pipe110, e.g., a water branch108off of pipe110configured for transferring water through the utility. The transverse pipe110can be formed using a T-fitting (e.g., fitting122) to create a monitoring junction or branch108. Branches108and/or pipes110can be located in designated spots along the piping infrastructure to install sensor-monitoring equipment. Air release valve112can be secured to housing102to facilitate bleeding the branch108and/or pipe110following a hot installation of the sensor coupling assembly100. Air release valve112facilitates the bleeding off of any trapped air in branch108and/or pipe110and enhances the functionality of the sensor coupling assembly100. In other aspects, housing102can define a minimum diameter312at sensor portion104and a maximum diameter312at gripping portion106. In various aspects, the maximum diameter312at the gripping portion106can be, for example and without limitation, less than 25%, 20%, 15%, 10%, or 5% greater than the minimum diameter312of the sensor portion104.

Sensor302can be located in a column of fluid, e.g., water, and inside a branch108defined by housing102outside the system's axial flow. Air and other impurities are released through the air release valve112so that sensor302can more accurately monitor the system. Seal206can be captured within angled sections320of housing102at the gripping portion106, and the tapered surfaces of gripping stop208interact with angled sections320to lock housing102(and the sensor coupling assembly100) onto the pipe end220of branch108and/or pipe110with an axial motion. Gripper flange402can be captured at the end of angled sections320and facilitates removal of housing102and sensor coupling assembly100. For example, by sliding the gripper flange in the upward direction, the angled sections are disengaged from the tapered surface of the gripper stop208, and the stopper assembly,100and/or housing102, can be removed and/or replaced from pipe end220without replacing branch108and/or pipe110. In various aspects, the sensor coupling assembly100can be removed and replaced or removed and repaired, such that the gripper flange402facilitates the removal and interchange of sensor coupling assemblies100at each branch108and/or pipe110.

With reference toFIGS.3-6, in various aspects, gripper flange402can be a unitary component of gripper stop208. Gripper flange402is illustrated inFIGS.4-6and can comprise a flange portion404and an insertion portion406. Flange portion404surrounds and extends radially from the insertion portion406, and both flange portion404and insertion portion can be defined by a flat profile (e.g., as shown inFIG.6) rotated around central axis118. Stated differently, both flange portion404and insertion portion406are arcuate or ring-shaped and have an “L-shaped” cross-sectional profile. As specifically illustrated inFIG.4, the flange portion404facilitates the operator to insert and/or release the insertion portion406of the gripper flange402. Insertion portion406securely couples sensor302, but the flange portion404can be used to remove and release the gripper flange402to remove sensor302from branch108.

Both gripper flange402and gripper stop208can form a single unitary part. For example, one or more of the gripper flange402and/or the gripper stop208can be a single monolithic part or piece. In this configuration, an operator could reach down on housing102to find the gripper flange402and, by pulling up on the gripper flange402in direction316, release the gripper stop208from branch108(e.g., pipe110) and remove housing102from pipe end220. In other aspects, gripper flange402can be a separate part or another component adjacent to gripper stop208and captured or trapped between angled sections320of housing102and pipe110. In this configuration, the operator would follow the same process to remove the sensor coupling assembly100from pipe end220but can bring a suitable gripper flange402(e.g., based on the dimensions or diameter of pipe110). When sensor coupling assembly100is coupled to pipe end220, housing102can comprise a pocket318filled as gripper stop208moves in an upward direction316relative to the downward direction314of housing102relative to pipe110to attach the sensor coupling assembly100at branch108securely.

With reference toFIGS.1-6, in some aspects, a method for installing the sensor coupling100comprises sliding housing102(comprising gripper stop208and sensor302) over pipe110. The gripper stop208can comprise a tapered surface and/or teeth222captured between housing102and pipe110to secure housing102to pipe110. For example, the housing102is secured to the branch108of pipe110by exerting an upward force, e.g., a force on the housing102in a direction opposite or away from the branch108of pipe110. The force on the housing102in a direction opposite from the branch108of pipe110compresses the tapered surface comprising teeth222and drives teeth222into the outer surface of branch108of pipe110to secure housing102on branch108of pipe110. In some aspects, the method can comprise releasing housing102from the branch108of pipe110by exerting another force on the gripper stop208. The force to release housing102is applied in the same direction, e.g., in a direction opposite from the branch108of pipe110, but the force is exerted on the gripper stop208rather than housing102.

The description is an enabling teaching of the present devices, systems, and/or methods in their best, currently known aspect. To this end, those skilled in the relevant art will recognize and appreciate that many changes can be made to the various aspects described herein, while still obtaining the beneficial results of the present disclosure. It will also be apparent that some of the desired benefits of the present disclosure can be obtained by selecting some of the features of the present disclosure without utilizing other features. Accordingly, those who work in the art will recognize that many modifications and adaptations to the present disclosure are possible and can even be desirable in certain circumstances and are a part of the present disclosure. Thus, the following description is provided as illustrative of the principles of the present disclosure and not in limitation thereof.

As used throughout, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to a quantity of one of a particular element can comprise two or more such elements unless the context indicates otherwise. In addition, any of the elements described herein can be a first such element, a second such element, and so forth (e.g., a first widget and a second widget, even if only a “widget” is referenced).

The word “or” as used herein means any one member of a particular list and also comprises any combination of members of that list. The phrase “at least one of A and B,” as used herein, means “only A, only B, or both A and B”; while the phrase “one of A and B” means “A or B.”

As used herein, unless the context clearly dictates otherwise, the term “monolithic” in the description of a component means that the component is formed as a singular component that constitutes a single material without joints or seams.

To simplify the description of various elements disclosed herein, the conventions of “left,” “right,” “front,” “rear,” “top,” “bottom,” “upper,” “lower,” “inside,” “outside,” “inboard,” “outboard,” “horizontal,” and/or “vertical” may be referenced. Unless stated otherwise, “front” describes that end of the seat nearest to and occupied by a user of a seat; “rear” is that end of the seat that is opposite or distal to the front; “left” is that which is to the left of or facing left from a person sitting in the seat and facing towards the front; and “right” is that which is to the right of or facing right from that same person while sitting in the seat and facing towards the front. “Horizontal” or “horizontal orientation” describes that which is in a plane extending from left to right and aligned with the horizon. “Vertical” or “vertical orientation” describes that which is in a plane angled at90degrees to the horizontal.

It should be emphasized that the above-described aspects are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the present disclosure. Many variations and modifications may be made to the above-described aspect(s) without departing substantially from the spirit and principles of the present disclosure. Further, the scope of the present disclosure is intended to cover any and all combinations and sub-combinations of all elements, features, and aspects discussed above. All such modifications and variations are intended to be included herein within the scope of the present disclosure, and all possible claims to individual aspects or combinations of elements or steps are intended to be supported by the present disclosure.