Ball Circulation Counter for Pipe Cleaning Accuracy
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Solution Overview
Problem
Existing methods for evaluating the cleaning efficiency of pipe lines using cleaning balls are inadequate as they rely solely on the number of balls circulated, failing to account for balls lost due to swirl or trapping, leading to inaccurate assessments of cleaning effectiveness.
Innovation Solution
A ball circulating apparatus that includes a counter capable of counting the number of balls over a predetermined period, calculating a ball circulation rate by dividing the counted balls by the input balls, and using a dual passage pipe system with a screen to prevent ball aggregation, allowing for precise counting and improved durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the number of cleaning balls circulated is used as the sole measure for evaluating cleaning effectiveness, then the assessment method is simple, but the evaluation accuracy is poor because it does not account for balls lost due to swirl or trapping
Solution Approach 1:
A passage pipe is introduced as an intermediary component to guide and separate cleaning balls from the cooling water flow. The passage pipe creates a controlled path that allows balls to pass through individually, enabling accurate counting while simplifying the overall system architecture compared to complex sensor arrays or tracking systems
Solution Approach 2:
The patent replaces complex mechanical counting mechanisms or electronic sensor systems with a simplified mechanical guidance structure (passage pipe) that naturally directs balls through a counting point, reducing system complexity while maintaining measurement precision
2Measurement precision
If a conventional counter with a transparent passage pipe and external sensor is used, then the structure is simple, but counting accuracy deteriorates because multiple aggregated balls are detected as a single ball
Solution Approach 1:
The passage pipe is designed with specific dimensions (diameter slightly larger than ball diameter) and internal features that segment the ball flow, ensuring balls pass through individually rather than aggregated. This segmentation occurs naturally through the pipe geometry without requiring additional separating mechanisms
Solution Approach 2:
The patent addresses the aggregation problem by introducing a spatial dimension constraint through the passage pipe's cross-sectional area, which is carefully sized to accommodate only one ball at a time, transforming the counting problem from a volumetric detection issue to a controlled sequential passage issue
3Reliability
If only the collection rate of cleaning balls is considered, then the assessment method is straightforward, but it fails to reflect the actual cleaning performance because some balls are not circulated due to swirl or trapping
Solution Approach 1:
The counter provides real-time feedback on the actual number of balls circulating through the system, enabling dynamic assessment of cleaning effectiveness. This feedback mechanism allows operators to distinguish between balls that are actively cleaning versus those lost to swirl or trapping, improving assessment reliability without significantly increasing procedural complexity
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
This method provides a more accurate assessment of pipe cleaning efficiency by considering both the number and time of balls circulated, improving the reliability of cleaning evaluations and reducing manufacturing costs through a simpler structure.
Implementation Method 1
a sensor is arranged on the outside of the passage pipe and emits infrared rays to detect balls flowing inside the passage pipe
Data Source
AI summary
The present invention relates to an apparatus for circulating balls. An embodiment of the present invention includes: a circulation path for circulating balls and fluid, the circulation path comprising a cooling water tube of a heat exchange unit; a pump arranged in the circulation path for pumping the balls and fluid; and a counter for counting the time and the number of the balls in relation to the circulation of the balls.