Compact Sampling Device for Direct Process Pipe Analysis
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Solution Overview
Problem
Existing systems for sampling, preparing, and analyzing suspensions in industrial processes are costly, bulky, and inefficient, leading to delayed process control due to the need for transporting samples through long pipes and separate central analysis devices, resulting in low measurement frequency and delayed feedback.
Innovation Solution
A compact device is placed directly adjacent to the process pipe, featuring a sampling unit connected directly to preparation units with filters and an optical analysis unit for measuring absorbance, reflectance, or fluorescence, allowing for direct sampling and analysis without intermediate transport, enabling faster feedback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a central preparation and analysing device is used for multiple measuring locations, then costs are reduced by using one device, but the analysing frequency decreases and feedback delay increases
Solution Approach 1:
The device is segmented into multiple independent preparation units (first preparation unit with first filter, second preparation unit with second filter) that can simultaneously process samples from different measuring locations. Each preparation unit operates independently to enable parallel analysis, thus maintaining high analysing frequency while keeping costs lower than having completely separate systems for each location.
Solution Approach 2:
The device is designed as a universal system that can handle samples from multiple measuring locations through a single optical analysing unit. The modular preparation units can process different sample types and the system can be configured for various measurement parameters (absorbance, reflectance, fluorescence), providing multi-functionality that reduces overall system cost while maintaining efficient operation.
2Adaptability or versatility
If samples are transported through long pipes to central analysis devices, then sampling can be done at remote locations, but analysis time increases and feedback is delayed
Solution Approach 1:
The device merges the preparation units and optical analysing unit into a single integrated system located at the same position. This combination eliminates the need for separate transport pipelines between sampling points and analysis devices, thereby reducing sample transport time and enabling faster feedback while maintaining the ability to sample at multiple locations through the distributed preparation units.
3Measurement precision
If complex sampling systems with multiple modules are used, then comprehensive analysis is achieved, but device size and cost increase
Solution Approach 1:
The complex sampling system is segmented into standardized, modular preparation units that can be replicated and combined. Each module contains essential components (filter, chamber) that perform specific functions, allowing the system to achieve comprehensive analysis capability through simple repetition of proven modules rather than requiring a single complex monolithic device.
Solution Approach 2:
The device uses filter elements (first filter, second filter) as core components in each preparation unit. These porous filtering structures enable separation and preparation of samples in a compact manner, achieving effective sample preparation without requiring complex mechanical systems. The filters provide reliable size-based separation that simplifies the overall device structure while maintaining analysis precision.
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 configuration reduces costs, minimizes contamination, and provides faster analysis and control feedback by eliminating the need for lengthy sample transport, enhancing process efficiency and product quality.
Implementation Method 1
an optical analysing unit for measuring any of the following: absorbance, reflectance, and fluorescence
Implementation Method 2
an optical analysing unit for measuring any of the following: absorbance, reflectance, and fluorescence
Implementation Method 3
an optical analysing unit for measuring any of the following: absorbance, reflectance, and fluorescence
Implementation Method 4
a first preparation unit with a first filter and a second preparation unit with a second filter
Data Source
Figure 1
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AI summary
A device (100) for sampling, preparing and analysing a sample, for example a suspension, comprises: a sampling device (A) adapted to sampling a fluid sample, at least one sample preparation unit (B, C) adapted to prepare the sample, and at least one analysing unit (D). By adapting the device for sampling and analysing a sample for placement in direct vicinity to a process pipe and adapting the sampling device to sample a fluid sample directly from a gate, a compact and cost-efficient device is provided, which also provides fast feedback to a process to be controlled.