Malleable sensor for filter bag

Abstract

A filter bag sensor system includes a malleable sensor system disposed on a filter bag, wherein the malleable sensor system provides a signal indicative of deformation of the filter bag.

Description

[0001] Cross-references to related applications This application claims the benefit of U.S. Provisional Patent Application Serial No. 63 / 595,627, filed November 2, 2024, entitled “Extensible Sensor For Filter Bags,” pursuant to 35 USC § 119, the contents of which are incorporated herein by reference. Technical Field

[0002] This disclosure generally relates to compliant sensor systems and methods for use with sensors that undergo bending, flexing, stretching, torsion, etc., to measure force, strain, stress, etc. More specifically, this disclosure relates to extendable sensor systems and methods for use with sensors configured to detect wear on filter bags, etc. Background Technology

[0003] Flexible sensors are known. For example, U.S. Patent Nos. 8,941,392, 9,222,764, 9,476,692, 9,612,102, 9,874,431, 10,551,917, 10,823,546, 10,959,644 and U.S. Patent Application Publication No. 2022 / 0034692 disclose flexible sensors, the contents of which are incorporated herein by reference.

[0004] Air filtration systems are also known. Typically, air is circulated by a fan or impeller to move air and any particulate matter through a filter, thereby removing particulate matter. In some industrial environments (e.g., sawmills, manufacturing plants, etc.), filters may include bag filters, which can be held in place on a cage or similar structure. When particulate matter accumulates on the outside of the filter bag, it is usually necessary to reverse the airflow or use a boosted airflow to shake off the particulate matter from the filter bag for collection and removal. Over time and with use, filters or filter bags may scratch, break, or otherwise become damaged. Current systems do not provide a method for monitoring wear and tear, relying solely on visual inspection, which is flawed, time-consuming, and inconvenient.

[0005] Similarly, in some environments (e.g., high humidity environments), particulate matter with high moisture content may not be removed from the filter by pulsed or reverse airflow. Likewise, current systems do not provide indications of removal failures and rely solely on visual inspection, which is flawed, time-consuming, and inconvenient.

[0006] In some environments and applications, shaking off too much particulate matter at once can also be harmful to collection and removal processes as well as other downstream equipment. Current systems and methods also suffer from other drawbacks, inconveniences, inefficiencies, and various other problems. Summary of the Invention

[0007] Therefore, the disclosed embodiments solve the above-mentioned and other disadvantages, inconveniences, inefficiencies, and various problems existing in the current systems and methods. Other advantages and efficiencies also exist in the disclosed systems and methods.

[0008] In this document, the terms “flexible,” “stretchable,” “compliant,” and “deformable” are used interchangeably to some extent and all mean that the described embodiments have a certain amount of flexure, stretching, compression, torsion, bending, etc.

[0009] It should be understood that, in this document, the terms “vertical,” “horizontal,” “lateral,” “up,” “down,” “top,” “bottom,” “left,” “right,” “inner,” “outer,” etc., can refer to the relative orientation or position of features in the disclosed devices and / or components shown in the figures. For example, “up” or “topmost” can refer to a feature positioned closer to the top of the page than another feature. However, these terms should be interpreted broadly to include devices and / or components having other orientations (e.g., inverted or tilted orientations, where top / bottom, above / below, above / below, up / down, and left / right can be interchanged depending on the orientation).

[0010] The disclosed exemplary embodiments include a stretchable capacitive sensor that can be mounted on the internal or external surface of the filter, or on a filter support structure, and is capable of detecting bending, stretching, and other deformations, which can be used to determine whether the filter material has deteriorated due to thermal degradation, mechanical degradation, chemical corrosion, etc. In some embodiments, the output of the stretchable capacitive sensor can be used to optimize the filter's pulse strategy and maintenance cycle. In other embodiments, the stretchable capacitive sensor can detect and track micro-tears and abrasions that occur in the filter bag over time. In some embodiments, the stretchable capacitive sensor can be used to detect high-moisture dust and particulate matter that fails to be shaken off the filter. In some embodiments, the stretchable capacitive sensor can be used to detect and prevent excessive material collection and shaking off at once, which could potentially cause material flow problems in the hopper below. Other embodiments also exist. Attached Figure Description

[0011] Figure 1 This is a schematic cross-sectional view used to form a stack of compliant sensor systems according to the disclosed embodiments.

[0012] Figure 2It is a multi-region angular displacement sensor according to the disclosed embodiments.

[0013] Figure 3 This is an illustrative example of a stretchable printed flexible capacitive sensor system according to the disclosed embodiments.

[0014] Figure 4 This is a schematic diagram of a typical existing bag filter system.

[0015] Figure 5 This is an exemplary illustration of a stretchable capacitive sensor system mounted on a filter bag according to a disclosed embodiment.

[0016] Figure 6A and Figure 6B This is a schematic cross-sectional view of a filter bag under normal filtration and normal pulse cleaning operation according to the disclosed embodiments.

[0017] Figures 7A and 7B are schematic cross-sectional views of exemplary sensor locations according to the disclosed embodiments.

[0018] Figures 8A to 8D are schematic side views illustrating exemplary sensor locations according to the disclosed embodiments.

[0019] While various modifications and alternatives may be made to the invention, specific embodiments have been shown by way of example in the accompanying drawings and will be described in detail herein. However, it should be understood that this disclosure is not intended to limit it to the specific forms disclosed. Rather, the invention is intended to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims. Detailed Implementation

[0020] Figure 1 This is a schematic cross-sectional view of the stack used to form the compliant sensor system 200. As shown, the dielectric layer 12 is located between the top electrode layer 2 and the signal electrode layer 16. Additionally, as schematically indicated, the peripheral electrode 140 electrically connects the top electrode layer 2 and the signal electrode layer 16. Other configurations are also possible.

[0021] In some embodiments, the top electrode layer 2 may include an elastomeric layer (e.g., silicone rubber) containing conductive particles, such as nanoparticles, including carbon black, nickel nanowires, silver nanoparticles, graphene nanosheets, graphene oxide, etc. Although in Figure 2The top electrode layer 2 is shown as a continuous layer, but it can also be a "grid" or otherwise discontinuous structure. The top electrode layer 2 may also include a printed circuit board (PCB) interface and multiple conductive trace pads for attaching PCBs, sensor traces, or other electronic devices to operate and control the sensor system.

[0022] In some embodiments, the dielectric layer 12 may include an elastomeric material (e.g., silicone rubber), and, if necessary, a certain amount of conductive material may be added therein, particularly according to factors such as the expected dielectric constant. Although Figure 1 While not drawn to exact scale, in some embodiments, the dielectric layer 12 is designed to be slightly smaller than the top electrode layer 2 so that the peripheral edges of the top electrode layer 2 are not covered by the dielectric layer 12 and allow electrical contact with the peripheral electrode 140 disclosed below.

[0023] In some embodiments, the signal electrode layer 16 may include an elastomeric material (e.g., silicone rubber) containing a conductive material, wherein the conductive material is, for example, nanoparticles such as carbon black, nickel nanowires, silver nanoparticles, graphene nanosheets, graphene oxide, etc., and is confined to the sensor region, wiring, and peripheral electrodes 140. Multiple sensor regions 20 (in...) Figure 3 The area labeled “sensing region” and used interchangeably with “sensor region” in this document can be distributed throughout layer 16 (see example). Figure 3 Sensor region 20 may include a conductive material region. Sensor region 20 and trace 22 (in Figure 3 The trace 22, labeled "signal trace line" and used interchangeably with "trace / traces" herein, is electrically connected and printed together with the signal electrode layer 16. As shown, embodiments of the signal electrode layer 16 may include peripheral electrodes 140 electrically connected to the top electrode layer 2 to provide electrical isolation, particularly for the entire sensor system. Other configurations are also possible.

[0024] Figure 2 This is a multi-region angular displacement sensor 800 according to the disclosed embodiment. As shown in the figure, Figure 1Embodiments of the disclosed sensor system 200 can be connected together to form an angular displacement sensor 800. For example, an angular displacement sensor 800 (single-region, multi-region, etc.) can be implemented by connecting sensor system 200A to a second sensor system 200B via an elastomer connector 802. Additional disclosures regarding the construction, operation, and implementation of such angular displacement sensors 800 can be found in U.S. Patent No. 10,551,917 entitled “Compliant Multi-Region Angular Displacement and Strain Sensors,” the disclosure of which is incorporated herein by reference in its entirety.

[0025] As will be understood by those skilled in the art who benefit from this disclosure, the angular displacement sensor 800 can be extended to multiple desired regions, as shown by the additional elastomer connector 802 and sensor system 200N. Other configurations are also possible.

[0026] Figure 3 This is a schematic example of a stretchable printed flexible capacitive sensor system 300 according to the disclosed embodiments. As shown, at least one sensing area 20 may be included in an elastomeric material and is provided with one or more signal traces 22 for electronic communication with other system circuits and components. Other configurations are also possible.

[0027] Figure 4 This is a schematic diagram of a typical existing pulse-jet bag filter system 400. (See diagram for example.) Figure 4 As schematically shown on the left (“normal operation”), one or more filter bags 402 can be held in place on a wire cage frame 404 (a portion of the filter bag 402 is removed to make the wire cage frame 404 visible). Airflow 406 (as indicated by the largest arrow) moves or flows through the filter bags 402 and enters a manifold or tube sheet 408 for recirculation as needed. A fan or impeller (not shown) is used to control the airflow 406. Particulate matter 410 (e.g., dust, sawdust, etc.) present in the airflow 406 is deposited on the outside of the filter bags 402. Other configurations are also possible, such as drawing the airflow 406 through the inside of the filter bags 402, so that the particulate matter 410 is trapped inside the filter bags 402.

[0028] In addition, such as Figure 4As shown on the right (“pulse cleaning”), in some embodiments, it is necessary to reverse the airflow 406R as a cleaning air pulse through the filter bag 402 and remove particulate matter 410 from the surface of the filter bag 402. Other configurations and cleaning methods (such as reverse airflow through the filter bag without using pulse jets and vibrator cleaning that vibrates the filter bag to remove dust) are also possible, and the sensor systems and methods disclosed herein are equally applicable to any system and method used for cleaning.

[0029] Figure 5 This is an exemplary illustration of a stretchable capacitive sensor system 200 mounted on a filter bag 402 according to a disclosed embodiment. As shown, the stretchable capacitive sensor system 200, together with associated control, monitoring, and power supply circuitry 202, can be mounted to the outer surface of the filter bag 402. In some embodiments, the stretchable capacitive sensor system 200 can be mounted to the inner surface of the filter bag 402, or multiple stretchable capacitive sensor systems 200 can be mounted on both the inner and outer surfaces of the filter bag 402. It will be apparent to those skilled in the art who benefit from this disclosure that the stretchable capacitive sensor system 200 can be used to monitor the degree (amount and direction) of strain, the number of times the filter bag 402 undergoes flexural (or pulsed) cleaning, failure conditions (e.g., tears, holes, etc.), and reduced bending due to particulate matter, etc. It will be apparent to those skilled in the art who benefit from this disclosure that the stretchable capacitive sensor system 200 and the disclosed elastomer material used therein are suitable for applications with large strain, exhibit full elastic recovery, and are resistant to chemical corrosion, impact, vibration, and fatigue. The disclosed stretchable capacitive sensor system 200 also provides high design flexibility, enabling application-specific designs, power supplies, data sampling rates, data communication, etc., and allowing for highly customizable sensitivity and positioning for each sensing area. Furthermore, the disclosed stretchable capacitive sensor system 200 features low power consumption, with operating current in the microamp range (depending on the sampling rate and the voltage supplying the circuitry). Other advantages also exist.

[0030] Figure 6A and Figure 6B This is a schematic cross-sectional view of a filter bag 402 under normal filtration and normal pulse cleaning operations according to the disclosed embodiment. Figure 6A As shown (and with) Figure 4 (Similar to the left side), the filter bag 402 is supported on the wire mesh cage 404 and is frequently rubbed against the wire mesh cage 404 due to the inward airflow 406, resulting in wear. Particulate matter (not shown in this figure) accumulates on the outer surface of the filter bag 402. Figure 6B As shown (and with) Figure 4 (Similar to the right side) During normal pulse cleaning, the airflow is reversed (as shown in airflow 406R), and the filter bag 402 expands and is subjected to outward pressure, thereby shaking particulate matter off the outer surface, which also leads to wear and tear.

[0031] Figures 7A and 7B are schematic illustrations of the position of an exemplary sensor system 200 according to the disclosed embodiments. As shown in Figure 7A, the stretchable capacitive sensor system 200 can be centered on one of the wires of the wire cage 404. In other embodiments shown in Figure 7B, the stretchable capacitive sensor system 200 can be centered between two wires of the wire cage 404. The orientation of any of the sensor systems 200 shown in Figures 7A and 7B utilizes a pivot point and allows for maximum deformation of the sensor system 200 and associated signals. It will be apparent to those skilled in the art who benefit from this disclosure that other orientations and positions are also possible for the sensor system 200, such as wrapping substantially around the entire circumference (inner or outer surface) of the filter bag 402 or positioning it along the length of the filter bag 402.

[0032] Figures 8A to 8D are schematic side views of the positions of exemplary sensor systems 200A to 200F according to the disclosed embodiments. As schematically shown in Figures 8A to 8B, sensor systems 200A, 200B, and 200C can be positioned at one or more locations longitudinally (i.e., "along the length direction") along filter bag 402 and have different lengths. As indicated in Figure 8C, sensor system 200D can also be oriented "diagonally" or in more than one direction as shown in 200E to measure in multiple directions. Additionally, as indicated in Figure 8D, sensor system 200F can be located inside filter bag 402, on the inner surface of filter bag 402, or on wire cage frame 404. Those skilled in the art who benefit from this disclosure will also understand that various combinations of orientations and positions can also be used. Furthermore, multimodal sensor systems 200 (e.g., those sensors that measure more than one parameter, such as strain, pressure, angular displacement, etc.) can also be implemented according to this disclosure.

[0033] While various embodiments have been shown and described, this disclosure is not limited thereto and will be understood to include all such modifications and variations, which will be apparent to those skilled in the art.

[0034] Exemplary embodiments include: 1. A filter bag sensor system, comprising: A stretchable sensor system is disposed on a filter bag, wherein the stretchable sensor system provides a signal indicating the deformation of the filter bag.

[0035] 2. The filter bag sensor system according to Exemplary Example 1, wherein the extendable sensor system further includes a capacitive sensor.

[0036] 3. The filter bag sensor system according to Exemplary Example 1, further comprising: A support structure for holding the filter bag in a predetermined direction, wherein the extendable sensor system is disposed at a pivot point of the support structure.

[0037] 4. The filter bag sensor system according to Exemplary Example 1, further comprising: A support structure for holding the filter bag in a predetermined orientation, wherein the extendable sensor system is disposed between the substantially rigid components of the support structure.

[0038] 5. The filter bag sensor system according to Exemplary Example 1, wherein the extendable sensor system is configured to be disposed at a pivot point of a support structure for holding the filter bag in a predetermined position.

[0039] 6. The filter bag sensor system according to Exemplary Example 1, wherein the extendable sensor system is configured to be disposed between substantially rigid components of a support structure for holding the filter bag in a predetermined position.

[0040] 7. The filter bag sensor system according to Exemplary Example 1, wherein the extendable sensor system is positioned substantially longitudinally along the length of the filter bag.

[0041] 8. The filter bag sensor system according to Exemplary Example 1, wherein the extendable sensor system is positioned substantially diagonally across the filter bag.

[0042] 9. The filter bag sensor system according to Exemplary Example 1, wherein the extendable sensor system is positioned substantially circumferentially around the filter bag.

[0043] 10. The filter bag sensor system according to Exemplary Example 1, wherein the extendable sensor system is positioned along the filter bag in at least two different directions.

[0044] 11. The filter bag sensor system according to Exemplary Example 1, wherein the stretchable sensor system further includes a multimodal sensor system.

[0045] 12. The filter bag sensor system according to Exemplary Example 1, wherein the stretchable sensor system is positioned on the inner surface of the filter bag.

[0046] 13. The filter bag sensor system according to Exemplary Example 1, wherein the extendable sensor system is positioned on the outer surface of the filter bag.

Claims

1. A filter bag sensor system, comprising: A stretchable sensor system is disposed on a filter bag, wherein the stretchable sensor system provides a signal indicating the deformation of the filter bag.

2. The filter bag sensor system according to claim 1, wherein, The extendable sensor system further includes a capacitive sensor.

3. The filter bag sensor system according to claim 1, further comprising: A support structure for holding the filter bag in a predetermined direction, wherein the extendable sensor system is disposed at a pivot point of the support structure.

4. The filter bag sensor system according to claim 1, further comprising: A support structure for holding the filter bag in a predetermined orientation, wherein the extendable sensor system is disposed between the substantially rigid components of the support structure.

5. The filter bag sensor system according to claim 1, wherein, The extendable sensor system is configured to be positioned at a pivot point on a support structure used to hold the filter bag in a predetermined position.

6. The filter bag sensor system according to claim 1, wherein, The extendable sensor system is configured to be disposed between the substantially rigid components of a support structure used to hold the filter bag in a predetermined position.

7. The filter bag sensor system according to claim 1, wherein, The extendable sensor system is positioned substantially longitudinally along the length of the filter bag.

8. The filter bag sensor system according to claim 1, wherein, The extendable sensor system is positioned substantially diagonally across the filter bag.

9. The filter bag sensor system according to claim 1, wherein, The extendable sensor system is positioned substantially circumferentially around the filter bag.

10. The filter bag sensor system according to claim 1, wherein, The extendable sensor system is positioned along the filter bag in at least two different directions.

11. The filter bag sensor system according to claim 1, wherein, The extendable sensor system further includes a multimodal sensor system.

12. The filter bag sensor system according to claim 1, wherein, The extendable sensor system is positioned on the inner surface of the filter bag.

13. The filter bag sensor system according to claim 1, wherein, The extendable sensor system is positioned on the outer surface of the filter bag.

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