Blower Vacuum Gauge Prevents Air Starvation in Bulk Loading
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Solution Overview
Problem
The existing systems for loading dry bulk materials into tank trailers using blowers as vacuums are prone to overheating and failure due to air starvation, which is not reliably monitored, leading to costly and time-consuming replacements.
Innovation Solution
A blower assembly with a vacuum gauge and check valve is mounted on a tank truck, allowing for real-time monitoring of vacuum pressure and automatic relief when the pressure exceeds safe limits, preventing overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the blower is operated as a vacuum to load dry bulk material into the tank trailer, then the loading efficiency is improved, but the blower may become starved of air due to filter clogging, leading to overheating and failure
Solution Approach 1:
The patent installs a vacuum gauge before the blower operation to monitor vacuum pressure in advance. This allows the operator to detect potential air starvation conditions before they cause overheating and failure, enabling preventive action rather than waiting for damage to occur.
Solution Approach 2:
The vacuum gauge provides continuous feedback on the vacuum pressure conditions to the operator. This feedback mechanism allows real-time monitoring of the blower's operating conditions, enabling the operator to respond to changing conditions and prevent air starvation before it leads to failure.
2Ease of operation
If the trailer filter is damaged or clogged, then the blower becomes starved of air and operates beyond maximum vacuum capacity, but there is no indication to the operator of the problem
Solution Approach 1:
The vacuum gauge mounted on the tank trailer provides continuous feedback to the operator about the vacuum pressure conditions. When filters become clogged or damaged, the vacuum pressure changes, and this is immediately reflected on the gauge, giving the operator timely warning to take corrective action before the blower fails.
Solution Approach 2:
The vacuum gauge acts as an intermediary device between the blower system and the operator. It translates complex internal system conditions (air flow restrictions, filter clogging) into simple, readable vacuum pressure readings that the operator can easily interpret and respond to.
3Reliability
If the blower is monitored for vacuum pressure, then overheating can be prevented, but the system complexity increases
Solution Approach 1:
The vacuum gauge provides a simple feedback mechanism that monitors vacuum pressure without adding significant complexity to the system. The gauge directly reads the vacuum pressure and provides immediate visual feedback to the operator, enabling protection against overheating through a straightforward, easy-to-understand interface.
Solution Approach 2:
The vacuum gauge is a passive monitoring device that automatically indicates vacuum pressure conditions without requiring active control or complex processing. It serves itself by directly measuring and displaying the relevant parameter, eliminating the need for additional control systems or complex monitoring infrastructure.
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 system effectively prevents blower overheating and failure by monitoring and controlling vacuum pressure, reducing the risk of costly replacements and ensuring continuous operation.
Implementation Method 1
the blower may also be operated as a vacuum to load the dry bulk material from the rail car into the tank trailer
Implementation Method 2
a vacuum gauge that is operable for monitoring a vacuum pressure of an airflow between the blower filter and the blower
Data Source
AI summary
A system for loading fry bulk materials into a tank trailer includes a blower assembly mounted on a tank truck that is in pneumatic communication with the interior of a tank of the tank trailer through at least one conduit. The blower assembly includes a blower and a blower filter in pneumatic communication with the blower through a suction line. The blower assembly further includes a vacuum gauge for monitoring the vacuum pressure of the airflow between the blower filter and the blower and an optional check valve for passing the airflow from the ambient atmosphere in the event that the vacuum pressure of the airflow exceeds a predetermined maximum vacuum pressure for safe operation of the blower. The predetermined maximum vacuum pressure may be no more than about five inches of mercury vacuum pressure (5 in-Hg; 2.46 psi). An operating vacuum pressure of the blower may be between about seventeen inches of mercury (17 in-Hg; 8.35 psi) and about five inches of mercury (5 in-Hg; 2.46 psi).