A SYSTEM AND METHOD FOR MANUFACTURING A SYSTEM

Abstract

A signal transmission system or a sensor system comprises at least one signal line and at least one sensor connected to the signal line, a first tube formed of a metal strip or metal plate having two longitudinal edges extending in a longitudinal direction and two transverse edges connecting the longitudinal edges, wherein the metal strip or metal plate is formed to a cavity by joining the longitudinal edges of the metal strip or metal plate together, and wherein the at least one signal line is located in the cavity. A method for manufacturing such a signal transmission system or a sensor system is also disclosed.

Claims

1. A system comprising: at least one signal line; at least one sensor connected to the at least one signal line; and a first tube formed of a metal strip or a metal plate having two longitudinal edges extending in a longitudinal direction and two transverse edges connecting the longitudinal edges, wherein the metal strip or metal plate is formed to a cavity by joining the longitudinal edges of the metal strip or the metal plate together, and wherein the at least one signal line and the at least one sensor is located in the cavity.

2. The system according to claim 1, wherein inside the cavity of the first tube a second metal tube is located, wherein the second metal tube comprises a groove in an outer surface thereof, wherein the groove extends in a longitudinal direction of the second metal tube, and wherein the at least one signal line is located in the groove.

3. An umbilical comprising the system according to claim 1, and at least one further strand.

4. A method for manufacturing a system comprising the steps of: providing at least one signal line connected to at least one sensor; providing a metal strip or a metal plate having two longitudinal edges extending in a longitudinal direction and two transverse edges connecting the longitudinal edges; forming a first tube with a cavity by joining the longitudinal edges of the metal strip or metal plate together; and placing the at least one signal line and the at least one sensor in the cavity.

5. The method according to claim 4, wherein the at least one signal line is placed on a surface of the metal strip or metal plate before forming of the cavity.

6. The method according to claim 5, wherein the at least one signal line is fixed on the surface of the metal strip or the metal plate.

7. The method according to claim 5, wherein the at least one signal line is placed on the surface of the metal strip or metal plate such the signal line extends in the longitudinal direction of the metal strip or metal plate.

8. The method according to claim 4, wherein the method further comprises the steps of providing a second metal tube and locating the second metal tube on the metal strip or the metal plate, and wherein the metal strip or the metal plate is bent around the second metal tube such that the second metal tube is placed in the cavity formed by the metal strip or the metal plate.

9. The method according to claim 8, wherein a groove is provided in an outer surface of the second metal tube, wherein the groove extends in a longitudinal direction of the second metal tube, and wherein the at least one signal line with or without at least one sensor connected to the signal line is placed in the groove.

10. The method according to claim 4, wherein forming the first tube with a cavity comprises a welding process.

11. The method according to claim 4, wherein forming the first tube with a cavity comprises a roll forming process.

12. A method for manufacturing an umbilical comprising the steps of providing a system using the method according to claim 4; providing at least one further strand; and assembling the system and the at least one further strand together.

13. The method according to claim 12, wherein the at least one further strand is a metal tube for conveying a fluid.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0059] FIG. 1 is a schematic perspective view of a metal strip or a metal plate used for forming a sensor system according to an embodiment of the present disclosure indicating steps a) and b) of a method for manufacturing the sensor system according to an embodiment of the present disclosure.

[0060] FIG. 2 is a schematic perspective view of a sensor system according to an embodiment of the present disclosure also indicating steps c) and d) of a method for manufacturing the sensor system according to an embodiment of the present disclosure.

[0061] FIG. 3 is a schematic perspective view of a sensor system according to a further embodiment of the present disclosure also indicating steps a) to d) of a method for manufacturing the sensor system according to an embodiment of the present disclosure.

DETAILED DESCRIPTION

[0062] In the figures, identical elements are denoted by identical reference numerals.

[0063] FIG. 1 shows a schematic perspective view of a metal strip 4 used for forming a sensor system 1 according to an embodiment of the present disclosure also indicating steps a) and b) of the method for manufacturing such a sensor system 1.

[0064] In accordance with step a) of the method for manufacturing a sensor system, multiple sensors 10 are provided together with a signal line 2. The sensors 10 are connected to the signal line 2 and are equally spaced along the length of the signal line 2.

[0065] In accordance with step b) of the method for manufacturing a sensor system 1, a metal strip 4 having two longitudinal edges 5 and two transverse edges 6 (not shown) is provided. The metal strip 4 is provided as a coiled strip 4 to manufacture a sensor system having a tube length of more than 100 meters.

[0066] After uncoiling the metal strip 4, the signal line 2 and the sensors 10 are aligned with the longitudinal edges 5 of the metal strip 4. The signal line 2 and the sensors 10 are affixed to the surface of the metal strip 4 by gluing, such that the sensors 10 are in engagement with the metal strip 4 and having a fixed positional relationship relative to the metal strip 4. Each of the sensors 10 is a combined acceleration sensor and force sensor capable for sensing movement of the metal strip 4 and force exerted on the metal strip. The sensors 10 are each connected to two copper wire together forming the signal line 2.

[0067] FIG. 2 indicates steps c) and d) of the method for manufacturing the system 1 according to an embodiment of the present disclosure resulting in a system 1 according to an embodiment of the present disclosure.

[0068] By roll forming the longitudinal edges 5 of the metal strip 4 are bend towards each other thereby forming a first tube 3 comprising a cavity 7. The longitudinal edges 5 are welded together thereby preserving the shape of the tube 3. Since the sensors 10 and the signal line 2 have been placed on the metal strip, when joining the longitudinal edges 5 of the metal strip 4 together so to form a cavity 7, the sensors 10 and the signal line 2 are located in the cavity 7.

[0069] At the end, the sensor system 1 comprises a first metal tube 3 protecting the sensors 10 and the signal line 2 against environmental influences.

[0070] The signal line 2 extends in the longitudinal direction of the first metal tube 3, wherein the ends of the signal line 2 protrude over the first metal tube 3, such that the signal line 2 is connectable to a receiver (not shown).

[0071] FIG. 3 is perspective view of a sensor system 1 according to another embodiment of the present disclosure also indicating the steps a) to d) of a corresponding method for manufacturing the sensor system 1.

[0072] In step a) a signal line 2 and sensors 10 are provided. The sensors 10 are connected to the signal line 2 and are equally spaced along the length of the signal line 2. The sensors 10 are pressure sensors so to determine a pressure exerting on the system 1.

[0073] Next, a metal strip 4 comprising two longitudinal edges 5 and two transverse edges 6 is provided. The latter connecting the longitudinal edges 5, wherein only one transverse edge 6 is shown in FIG. 3.

[0074] A second metal tube 8 is placed on a surface of the metal strip 4. The second metal tube 8 is a seamless tube provided by cold drawing of a hollow through a drawing die (not shown). The drawing die has an inner tool forming an outer surface of the second metal tube 8, and wherein the inner tool surface comprises a protrusion projecting inwardly such that a groove 9 is drawn into the outer surface of the second metal tube 8.

[0075] The groove 9 extends in a longitudinal direction of the second metal tube 8. In a subsequent step the signal line 2 and multiple sensors 10 are placed in the groove 9.

[0076] After the signal line 2 and the sensors 10 have been placed in the groove 9, the metal strip 4 is bent to a first tube 3 by roll forming. After roll forming the first tube 3 surrounds the second metal tube 8. The second metal tube 8 is thereby placed inside the cavity 7 formed by the first tube 3. The first tube 3 and the second tube 8 are in force fit engagement with each other. The longitudinal edges 5 of the metal strip 4 are welded together, thereby preserving the shape of the first metal tube 3.

[0077] Since the second metal tube 8 is placed in the cavity 7, the groove 9 faces an inner surface of the first metal tube 3, such that the signal line 2 and the sensors 10 are arranged between the first tube 3 and the second tube 8. The at least one signal line 2 placed in the groove 9 as well as the sensors 10 are protected by both, the first metal tube 3 and the second metal tube 8.

[0078] For purposes of original disclosure, it is pointed out that all features which are apparent for a person skilled in the art from the present description, the figures and the claims, even if they have only been described with further features, could be combined on their own or together with all the combinations of the features disclosed herein, if not excluded explicitly or technically impossible. A comprehensive explicit description of all possible combinations of features is only omitted in order to provide readability of the description.

[0079] While the disclosure has been described with respect to a limited number of embodiments, it will be understood that the disclosure of which is not limited to those embodiments. Other embodiments comprising various changes do not depart from the scope of the disclosure. In particular, the description of preferred embodiments shall not be understood to be limited to what is explicitly shown and described in the specification and drawings but shall encompasses the disclosure of the specification and drawings as a whole.

LIST OF REFERENCE NUMERALS

[0080] 1, 1 system [0081] 2 signal line [0082] 3 first tube [0083] 4 metal strip [0084] 5 longitudinal edge of metal strip 4 [0085] 6 transverse edge of metal strip 4 [0086] 7 cavity [0087] 8 second tube [0088] 9 groove [0089] 10 sensor