Industrial Cleaning Machine Autonomous Control and Energy Recovery
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Solution Overview
Problem
Existing industrial cleaning machines for spray guns face challenges in ensuring compliance with safety requirements, such as ATEX directives, and lack efficient remote monitoring and maintenance capabilities.
Innovation Solution
An industrial cleaning machine equipped with a control device that monitors and controls the cleaning process autonomously using a battery-powered system. The control device communicates status information to a remote server, includes sensors for environmental and operational parameter measurement, and features a turbine generator for battery recharging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a control device is added to monitor and control the cleaning machine operation, then reliability and safety compliance are improved, but device complexity increases
Solution Approach 1:
The control device operates autonomously, automatically monitoring cleaning liquid concentration, controlling pump operation, and managing battery charging without requiring external intervention. The system self-regulates based on sensor feedback, eliminating the need for complex manual control systems while maintaining high reliability and safety compliance.
Solution Approach 2:
The control device receives continuous feedback from sensors monitoring cleaning liquid concentration, battery charge status, and pump operation. This feedback enables automatic adjustment of system parameters to maintain optimal cleaning performance and safety compliance without increasing operational complexity.
2Ease of operation
If a battery-powered control device is used to operate autonomously, then ease of operation and safety compliance are improved, but use of energy increases
Solution Approach 1:
The system recovers compressed air energy that would otherwise be wasted and uses it to recharge the battery through a turbine generator. This energy recovery mechanism significantly extends battery operating life and reduces the frequency of charging cycles, making autonomous operation more practical without increasing overall energy consumption.
Solution Approach 2:
The control device operates in periodic cycles, alternating between monitoring/measuring modes and communication modes. The low-power wide area network transceiver communicates status information periodically rather than continuously, minimizing energy consumption while maintaining autonomous operation capability.
3Productivity
If remote monitoring capability is added via transceiver, then productivity and maintenance efficiency are improved, but device complexity increases
Solution Approach 1:
The patent replaces complex wired communication systems with a low-power wide area network transceiver that uses wireless electromagnetic communication. This substitution simplifies the physical connections required while enabling remote monitoring and maintenance capabilities, improving productivity without proportionally increasing system complexity.
4Duration of action of stationary object
If turbine generator is added for battery recharging, then duration of action is improved, but device complexity increases
Solution Approach 1:
The system converts wasted compressed air energy, which would normally be discharged uselessly, into useful electrical energy to recharge the battery. This transforms a harmful waste product into a beneficial resource, extending battery operating life without requiring external power sources or significantly increasing system 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
The solution ensures reliable operation and maintenance of the cleaning machine, provides cost-efficient operation, and allows for real-time monitoring and notification of maintenance needs, thereby enhancing safety and efficiency.
Implementation Method 1
The battery is rechargeable by means of a turbine generator that forms part of the air circuit and is operated by the compressed air supplied to the cleaning machine
Data Source
AI summary
An industrial cleaning machine for cleaning parts, in particular spray guns and accessories thereof, including a cleaning chamber for receiving parts, and a pneumatically operated cleaning system capable of subjecting the parts to a cleaning operation using a cleaning liquid. The cleaning system includes at least one pneumatically actuated pump that is operated by compressed air supplied to the cleaning machine to pump and supply the cleaning liquid from a container. The cleaning machine integrates a control device configured to monitor and control operation of the cleaning machine and to operate autonomously on power provided by a battery. The control device is configured to gather status information relating to operation of the cleaning machine and communicate the status information to a remote server. The control device includes an air circuit configured to be coupled to an air compressor to control supply of the compressed air to the pneumatically actuated pump.