Method and apparatus for automated particulate extraction from solid parts
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Solution Overview
Problem
Traditional methods for extracting non-dissolved particulates from solid parts using liquid cleaning media suffer from Type I and Type II errors due to inadequate contamination tracking and verification, leading to inefficiencies and inaccurate cleanliness assessments, particularly in machines used for testing parts with varying surface areas.
Innovation Solution
An automated particulate extraction process incorporating an in-line liquid quality sensor to monitor contamination levels during the cleaning process, ensuring both the parts and the test equipment meet cleanliness thresholds, with a removable measurement filter bypass to prevent false negatives and allow for continuous testing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional single contamination test per part is used, then testing speed is maintained, but Type I and Type II errors occur due to inadequate contamination tracking
Solution Approach 1:
The patent implements real-time feedback by continuously monitoring contamination levels in the liquid cleaning medium using an in-line liquid quality sensor. The sensor provides continuous data on contaminant concentrations, allowing the system to track contamination accumulation throughout the cleaning process and adjust operations accordingly, thereby eliminating Type I and Type II errors while maintaining testing efficiency
Solution Approach 2:
The patent replaces traditional mechanical filter-based contamination detection with an optical/in-line liquid quality sensor system. This substitution enables continuous, real-time monitoring of contamination levels in the cleaning medium without requiring manual filter changes or interruptions to the testing process, thus maintaining productivity while improving measurement accuracy
2Reliability
If residual contamination accumulates in test tank from processing larger parts, then subsequent smaller parts may fail tests due to Type II errors, but implementing frequent tank cleaning reduces productivity
Solution Approach 1:
The in-line liquid quality sensor provides continuous feedback on contamination accumulation in the test tank, allowing the system to monitor contaminant levels throughout the cleaning process. This real-time data enables determination of when the tank requires cleaning based on actual contamination levels rather than fixed schedules, preventing Type II errors while optimizing testing throughput
Solution Approach 2:
The patent implements dynamic contamination threshold monitoring where the system adjusts cleaning triggers based on real-time contamination levels in the liquid medium. Rather than using static cleaning intervals, the system dynamically responds to actual contamination accumulation rates, allowing continuous testing when contamination levels are low and triggering cleaning only when thresholds are exceeded, thus maintaining both reliability and productivity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively reduces Type I and Type II errors by ensuring accurate cleanliness assessments and efficient machine operation, allowing for real-time contamination monitoring and verification, thereby improving the reliability and efficiency of the cleaning process.
Implementation Method 1
the liquid quality sensor repeatedly measures the amount of a contaminant in the liquid exiting the tank
Data Source
AI summary
A method and apparatus for automated particulate extraction from solid parts is disclosed herein, which comprises a test tank (42) and a liquid cleaning medium (46) for washing a test part (48). The principle advantages offered by this invention include the ability to verify that the test tank (42) has met a required tank clean threshold (102) as specified by a percentage reduction of contaminants (78) through the use of a liquid quality sensor (76) which repeatedly measures the contamination level of a liquid cleaning medium (46) exiting the test tank (42). Type I and Type II sampling error are eliminated by verifying that the liquid cleaning medium (46) passing from the test tank (42) has measured contaminants (78) reaching both a maximum value (98) and then falling below a specified tank clean threshold (102) prior to ending the cleaning cycle.