Fully automatic cleaning and testing system for catalysts and filters for reuse

Abstract

The washing and testing device for catalysts and filters automates the process of testing and washing exhaust catalysts and filter vehicles. By placing the component in the device reservoir, an endoscopic image from inside the catalyst is obtained to determine the internal integrity of the component. Subsequently, a pressure pump and sensor test the component for defects by introducing compressed air. Based on the information gathered by the sensors from the component, the concentration of the washing liquid, solution temperature, and input pressure is adjusted, and a variable pump is used to introduce liquid at non-uniform pressure for an improved washing process. During washing, control sensors monitor the output liquid, adjusting temperature and concentration as needed, signaling the end of washing. After completion, the system enters the drying phase where hot air is introduced under pressure. Finally, a health check and gas test are conducted to ensure compliance with standards.

Description

Fully automatic cleaning and testing system for catalysts and filters for reuse

[0001] The catalyst and filter washing and testing device automates the testing and washing process for exhaust catalysts and filter vehicles. Once the component is placed in the device reservoir, an endoscopic image is captured to assess the internal integrity of the catalyst. Following this, a pressure pump and sensor are used to check for defects by introducing compressed air into the component. The information collected by the sensors is then used to adjust the concentration of the washing liquid, solution temperature, and input pressure, and a variable pump is employed to introduce liquid at varying pressures for more effective washing. Throughout the washing process, control sensors monitor the output liquid and make adjustments to the temperature and concentration as needed, signaling the completion of the washing phase. After this, the system moves into the drying phase where hot air is applied under pressure. Finally, a health check and gas test are carried out to ensure compliance with standards.

[0002] B01D 46 / 02 F01N 3 / 023

[0003] CN207620884 - Car catalyst converter with cleaning device

[0004] The utility model discloses a car catalyst converter with a cleaning device, including catalyst converter shell, purifier, filter, cleaning device, and clean spray tube, catalyst converter shell left side is equipped with a purifier, the purifier right side is equipped with the filter, the filter upside is inlayed and is had cleaning device, cleaning device passes through the gas -supply pipe and connects clean spray tube, clean spray tube inlay in on the filter, through be stained with activated carbon particle on the filter paper of filter, can improve dust and the particulate matter of filter into automobile exhaust and adsorb to improving the filter effect of the filter, through setting up cleaning device on the car catalyst converter, clean the discharge to dust on the filter and particulate matter, the normal use of assurance device prolongs the life of car catalyst converter.

[0005] The mentioned invention is also a cleaning device for catalysts, while our claimed invention is also equipped with sensors to check the pieces and the device's general well-functioning, and this feature prevents the device from damaging the catalyst and more importantly, it is done automatically, without needing someone to set it.

[0006] CN211189430 - Converter catalyst cleaning device

[0007] The utility model discloses a catalyst cleaning device of a converter. The device comprises a separator, a screening machine, and a dust removal filter box, a first stop valve is arranged at the outlet of each layer of the converter; an outlet of each first stop valve is connected with an inlet of the separator through a discharge pipeline; a particle outlet in the bottom of the separator is connected with an inlet pipeline of the screening machine, a dust outlet in the top of the separator is connected with an inlet pipeline of the dedusting filter box, an outlet of the dedusting filter box is connected with an inlet pipeline of the vacuum pump, and an outlet of the vacuum pump is connected with the blow-down pipe. The device has the advantages that the separator can effectively separate the agranular catalyst from a powdery catalyst, and the vacuum pump can suck the powdery catalyst into the dust removal filter box, so that the problem of dust raising generated in the catalyst cleaning process is solved; in a negative pressure state, the vacuum pump can suck the catalyst in the converter, so that the working efficiency is high, and the manpower is saved; and the bag-type dust collector can treat flying dust generated in the sorting process of the screening machine so that the surrounding working environment and the health of staff are guaranteed.

[0008] The mentioned invention is also a cleaning device for the catalyst, while our claimed invention also has sensors that prevent the device from damaging the catalyst and the whole washing process is automatic.

[0009] JP5709862B2- Method and apparatus for cleaning an exhaust filter for a vehicle

[0010] The present invention relates to a method and apparatus for cleaning particulate filters and other components of a vehicle exhaust system related to emission regulations from a diesel engine. If the filter is surrounded by a solid outer casing and has a rigid filter membrane or filter cell structure, the manufacturing process may be suitable for cleaning any type of filter.

[0011] The invention above differs from ours in its method of functioning, as well as lacking sensors, and our invention works automatically despite the other similar devices.

[0012] A fully automated cleaning and testing system for catalysts and filters includes components such as a pressure gauge, PLC system, video scope, air compressor, air storage, control and care unit, diaphragm valve, element, sensors, and more. After the washing process, the computer manages a functionality test using commands for the 5-gas analyzer in collaboration with sensors and commands for the final test. The system water undergoes treatment, and the wastewater is evaluated with a quality check device at the piece's outlet. Sensors measure the air entering and exiting throughout the entire test, relaying the results to the computer system.

[0013] in all the new cars, expensive filters and catalysts are installed on the industrial machinery for optimizing the fuel consumption and controlling the pollutants. This invention aims to recover the filter and the catalysts for reuse. To do so, an accurate device is needed, so that it can remove the oil and soot from inside the holes, without damaging the catalyst. Removing oil and soot needs high pressure and a soluble substance with high-temperature water with accurately calculated amounts, or it directly affects the quality and functionality of the catalyst. Otherwise, the recovery process is not done at all.

[0014] The invented device detects the sensors and diagnostic tools inside the device and determines the catalyst material and the degree of microscopic pore clogging to choose the best plan for recovering the catalyst without damage based on what is needed and by controlling the temperature, the water, and air pressure that enters the catalyst, and also the amount of the soluble substance (that does not have to cause corrosion to the piece).

[0015] devices in the market do the whole washing process and catalyst recovery manually and based on experience, with low quality and accuracy that do not detect and control the mentioned items.

[0016] Similar devices in the market include:

[0017] 1- Non-automatic manual washing devices: this sample is not a real device and has a manual pump with storage for washing substances that puts the catalyst in a plastic bowl this pump pushes the water into the catalyst and the user knows when the catalyst is recovered. This action is based on experience and is unscientific.

[0018] 2- the non-automatic manual devices: these types of devices do not have smart testing and controlling devices and diagnostic process setting sensors. This device works based on the person’s experience and the whole washing process is done manually, without any quality check and test and level control. (It is not a registered invention and is a simple manual device).Solution of problem

[0019] There are sensors and diagnostic tools for measuring the clogging and the hardness type of soot and also the catalyst material, to execute the best recovery plan, which includes setting the air and water pressure and the soluble liquid inside the catalyst and if any of these cases are not accurate, it causes corrosion to the catalyst and makes the microscopic holes bigger. The invented device has a testing tool for the mentioned items which changes the temperature, the washing substance, and the pressure in case of necessity, and the whole process is controlled automatically which reduces human errors. the testing tools are also installed to check the accuracy of the process after the recovery is over and determine the well-functioning of the catalyst.

[0020] The device function:

[0021] First, we connect the plug to the main electricity current. Then, we turn on the residual current device and the display control unit turns on to prevent any casualties and financial loss. A locking software system that enters the workspace after entering the device password has been installed on the device by default.

[0022] Initial test phase:

[0023] Before connecting the catalyst to the device, the heating system of the washing water and washing substance activates, and the washing water and washing liquid temperature is set from the display unit. The duration of the preparation process depends on the water volume and substance, about 20-30 minutes. After the catalyst (DPF) is placed on the device's working desk, then we connect the test connector by using a connector fastener to the initial system and we close the device door and activate the test bottom on the device, and by the activation of the system, the blower test starts working and the produced air enters the catalyst by using the connector which is connected to the catalyst and exit from the other side and the air current is measured until reaching the catalyst and a piece named manometer and debit meter that measures the entering air pressure to the catalyst and it sends the results to the device computer system and after declaring the results, the blower turns off automatically and the initial report from the catalyst clogging status is sent to the operator and then, based on the sensor report, a washing plan is offered to the operator and the operator can start working with the offered plan or set the washing plan manually.

[0024] The washing phase:

[0025] In the first step, the test connector is detached from the catalyst, and the red washing connector is connected to the end part of the catalyst which is the smoke outlet of the catalyst. Then the special valve is connected to the catalyst door and by using belt connectors, the catalyst is fixed on the device, so that it does not move by water and air pressure, during the washing process. Then the device door is closed and the washing plan is activated manually or automatically. After the activation of the washing order, first, the water pump pumps hot water (60-90 degrees) in the device based on the catalyst volume and prewashes inside the catalyst this plan takes long for 5 minutes, and then the washing substance pump starts to work and it cleans inside the piece from any soot or mass, then the water pump starts to work and the water enters the piece and it starts working by consecutive connection and disconnection, with a few reasons: washing the whole surface of the piece with a wave pattern that makes the soot and mass from inside the catalyst to separate from inside the device with the wave going back and the water and washing substance penetrates the internal mass which in this while, by using compressed air in pulse form(connecting and disconnecting), it pushes the water inside the piece and opens the smoke trail inside the piece and guides it to outside. In the trail of entering compressed air into the air storage, a dryer device and a degreaser of compressed air are installed, so that they do not enter the piece in the process of washing the oil.

[0026] While washing, the wastewater that contains mass and soot is guided to the clean water storage, after complete treatment. While washing with the washing substance and water, the pressure, temperature, and water hardness, as well as the compressed air are in control to prevent damage to the inside wall and the ceramic inside the piece, and also to prevent the water hardness to make sediment on the walls. In the mentioned device, a water treatment device is installed, because if the water hardness and the limestone of the water make sediment on the inside wall and ceramic, it makes the catalyst get clogged faster than the predicted time.

[0027] Drying phase:

[0028] In this phase, the washing connector is detached from the piece, and the blue test connector is attached to the smoke inlet, and the moisture and pressure sensor as well as the output sensor are installed and then we close the device door and activate the drying phase. The blower starts to work in this phase and the air passes an air heating device before entering the piece which makes the air temperature rise and the drying time of the piece to reduce. This process continues until the device is completely dry and the piece's moisture level is measured with a moisture sensor.

[0029] The final test phase:

[0030] After the blower and the air heater turn off automatically, the device enters the testing phase and the operator installs a pollutant sensor on the piece outlet or it starts by the order of the operator. In this phase, five automobile outlet gases are produced and sent into the piece and they are measured before the entrance. the outlet sensor is also tested after exiting, and by doing this, the blower and the air heater start to work simultaneously and this is also measured in the piece outlet. The device's computer system provides the operator with a complete report of how the piece works and how much the piece is recovered, which is mostly recovered between 90-98 percent.Advantage effects of the invention

[0031] - reduction of human errors

[0032] – high accuracy

[0033] – eliminating the damage possibility of the catalyst

[0034] – the addition of the controlling system and pump with variable washing debit and with more accuracy and quality

[0035] – washing substance quality control by the pressure setting system

[0036] – preventing the catalyst damage

[0037] – reducing the processing time

[0038] – reducing the costs

[0039] – having a catalyst dryer system

[0040] – well-functioning check of the device

[0041] :

[0042] 1- DPF catalyst

[0043] 2- water tank

[0044] 3- wastewater pump

[0045] 4- the washing substance pump

[0046] 5- the compressed air storage

[0047] 6- five gas analyzer

[0048] 7- the air blower

[0049] 8- the washing substance storage

[0050] 10- the testing device of the pollutant gas

[0051] 11- psychrometer

[0052] 12- Manometer Gauge for measuring the outlet pressure of the catalyst

[0053] 13- The diesel catalysts retainer

[0054] 14- dryer and catalyst pressure test - DPF

[0055] 15- Washing hose and catalyst detergent hose- DPF

[0056] 16- exhaust catalyst bung

[0057] 17- the cabin air outlet

[0058] 18- pneumatic jack

[0059] 19- the wastewater treatment storage

[0060] 20- Control board panel

[0061] 21- the manometer of the catalyst inlet

[0062] 22- the dryer air element

[0063] : A fully automatic cleaning and testing system for catalysts and filters for reuse has been developed. The system automates the testing and washing process for exhaust catalysts and filter vehicles. It includes sensors to prevent damage to the catalyst and operates automatically without the need for manual intervention. The system consists of a washing phase, a drying phase, and a health check and gas test to ensure compliance with standards. This invention aims to recover the filter and the catalysts for reuse in industrial machinery.Examples

[0064] A metal body is produced with a pressing method and electricity system plus the radars are installed on it. Then the motor and pumps are placed at their right place and are connected with connectors (the air pump with high-pressure hoses and water pump with hose and pipe from the water tank and washing substance storage to where the catalyst is placed), then the computer and control board is placed on the device and are connected to the sensors and diagnostic radars and in the end, the washing storage and the catalyst are placed based on the hydraulic jacks to engage and stop different phases of washing and test while being connected to the control board.

[0065] It is used in all the repair shops and factories that provide periodic maintenance services.

Claims

A Fully automatic cleaning and testing system for catalysts and filters for reuse including:A pressure gaugePLC systemVideo scopeair compressorair storagecontrol and care unitdiaphragm valveelementLiquid level gaugeLiquid level sensorTemperature sensorGas sensorFive gas analyzerpumpAccording to the claim. 1, a video scope, after checking inside the piece and confirmation that the pump is well-functioning, enters the piece and involves the air compressor, and the washing liquid and air enter the piece with pressure and the sensors check the water temperature and the device well-functioning and the pressure ratio, as well as controlling the amount of the washing liquid and then they diagnose the end of the process.According to the claim. 2, after the end of the washing process, the computer manages the well-functioning test with commands to the 5-gas analyzer with the cooperation of sensors and commands for the final test.According to the claim. 3, the washing water pump gets command directly from the computer system(plc), sets the pressure, and debits based on the primary test.According to the claim. 4, the system water is treated and the wastewater is tested with a quality check device, at the outlet of the piece.According to the claim. 5, the sensors measure the entering and exiting air the whole test time and send the results to the computer system, and the device sets the washing plan and presents it to the operator, and the inlet and outlet pressure, as well as the primary photo with the customer’s information, is registered on the device.

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