Centrifuge Automatic Sampling Control System
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Solution Overview
Problem
Existing centrifuge systems require manual sampling and control input by operators, leading to time delays and increased operating costs due to the need for continuous sampling and analysis, posing safety risks and inefficiencies.
Innovation Solution
A centrifuge system with automatic sampling and analysis capabilities, utilizing a computer connected to variable frequency drive units for the bowl, conveyor, and pump motors, which automatically samples slurry and effluent streams, calculates control schemes, and transmits control signals to operate the motors based on real-time data without operator intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If manual sampling and control input is used, then the operator can analyze samples and determine control parameters, but there is a time delay between obtaining samples and inputting set points
Solution Approach 1:
The system performs self-sampling through automatically actuated sampling ports that retrieve samples without operator intervention. The control system automatically processes sample data and adjusts centrifuge parameters, enabling the system to service itself and eliminating the time delay associated with manual sampling and control input.
Solution Approach 2:
The patent replaces manual mechanical sampling operations with automated fluid handling systems. Computer-controlled actuators open sampling ports and transfer samples to analysis instruments, substituting the mechanical manual process with an automated electromechanical system that eliminates time delays.
2Reliability
If almost continuous manual sampling is performed to accurately control the centrifuge in real time, then control responsiveness improves, but operating costs increase due to dedicated personnel requirements
Solution Approach 1:
The centrifuge system continuously self-monitors through automated sampling ports and analysis instruments that are always active. The control system continuously receives data from these instruments and automatically adjusts operating parameters, eliminating the need for dedicated personnel while maintaining continuous control responsiveness.
Solution Approach 2:
The system implements continuous automated sampling and analysis rather than periodic manual sampling. Samples are continuously drawn through automatically actuated ports and analyzed in real-time, ensuring uninterrupted monitoring and control while eliminating the need for dedicated operator attention.
3Ease of operation
If the operator is in the immediate proximity of the centrifuge for sampling, then samples can be obtained directly, but safety risks increase due to the size, mass, and speeds of the centrifuge
Solution Approach 1:
The system introduces automated sampling ports and remotely actuated valves as intermediaries between the operator and the centrifuge. These intermediaries allow sample retrieval without requiring the operator to be near the moving centrifuge components, eliminating safety risks while maintaining sampling capability.
Solution Approach 2:
The patent replaces manual sampling operations near the centrifuge with remotely actuated automated sampling systems. Computer-controlled valves and actuators open sampling ports and transfer samples through sealed lines to remote analysis instruments, substituting the dangerous manual process with a safe automated system.
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
Enables real-time control of the centrifuge operations, reducing operator workload, minimizing safety risks, and optimizing performance by automatically adjusting bowl and conveyor speeds and pump flow rates, thus enhancing operational efficiency and reducing costs.
Implementation Method 1
A centrifuge for centrifuging a slurry, including: a bowl driven by a bowl drive motor; a screw conveyor driven by a screw conveyor drive motor
Data Source
Figure 1
Figure 2
AI summary
A centrifuge 10 for centrifuging a slurry. The centrifuge 10 comprising a bowl 11 driven by a bowl drive motor 19, a screw conveyor 12 driven by a screw conveyor drive motor 21, a pump 15 driven by a pump motor 35, a bowl variable frequency drive unit (VFD) 32 operatively arranged to drive the bowl drive motor 19, a conveyor VFD 31 operatively arranged to drive the screw conveyor drive motor, a pump VFD 34 operatively arranged to drive the pump drive motor 35, a first analysis assembly 50A and at least one computer 30 electrically connected to the bowl VFD 32, the conveyor VFD 31, the pump VFD 34 and the first analysis assembly 50A. The first analysis assembly 50A is configured to automatically sample a liquid effluent discharged from the centrifuge 10 and automatically transmit first data, characterizing the liquid effluent, to the at least one computer 30. The at least one computer 30 is configured to calculate respective control schemes for the bowl VFD 32, the conveyor VFD 31, and the pump VFD 34 using the first data. The at least one computer 30 is also configured to transmit respective control signals to the bowl VFD 32, the conveyor VFD 31, and the pump VFD 34 to operate the bowl VFD 32, the conveyor VFD 31, and the pump VFD 34, according to the respective control scheme. The at least one computer 30 is also configured to receive a first input quantifying a torque load 90 on the conveyor motor 21, vary a first differential speed between the bowl 19 and the conveyor 21 until the torque load 90 increases by a first degree 96 at a second differential speed 94A between the bowl 19 and the conveyor 21, calculate a third differential speed 94B based on the second differential speed and operate the bowl 19 and conveyor motors 21 to maintain the third differential speed.