Diaphragm Compressor Leak Groove Layout for Fluid Separation
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Solution Overview
Problem
Existing leakage detection systems for diaphragm compressors fail to effectively detect leaks when sensors fail and cannot determine the amount of leaked gas in a mixture of working fluid and gas fluid.
Innovation Solution
A diaphragm compressor design with a multi-layered diaphragm and separate compression chambers for process and hydraulic fluids, featuring grooves and seals to guide leaked fluids to dedicated detection systems, allowing for independent detection of process and hydraulic fluid leaks without contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor is used to detect leaked gas or mixed gas fluid and working fluid, then leakage detection is enabled, but the system cannot determine the amount of leaked gas in the mixture and cannot continue detecting if the sensor fails
Solution Approach 1:
The patent separates the detection of process fluid leaks from hydraulic fluid leaks by providing separate detection systems for each fluid type. The process fluid detection system includes a process fluid detection sensor and associated grooves, while the hydraulic fluid detection system includes a hydraulic fluid detection sensor and associated grooves. This segmentation allows each sensor to detect only its designated fluid type, enabling accurate determination of leaked gas amounts without contamination from the other fluid.
2Reliability
If process fluid and hydraulic fluid leaks are detected in a mixed system, then leakage detection is achieved, but the leaked process fluid becomes contaminated by hydraulic fluid making detection harder
Solution Approach 1:
The patent implements separate detection systems for process fluid and hydraulic fluid, with dedicated detection sensors and separate groove systems for each fluid type. This prevents contamination between fluid types and maintains reliable detection accuracy for each fluid independently.
Solution Approach 2:
The patent introduces separate groove systems as intermediary pathways that guide each fluid type to its own detection system. The process fluid leak groove system guides process fluid to the process fluid detection sensor, while the hydraulic fluid leak groove system guides hydraulic fluid to the hydraulic fluid detection sensor, preventing direct mixing and contamination.
3Stability of the object's composition
If the distance between the seal groove and outer leakage groove is increased to ensure seal fixation under high pressure, then seal stability is improved, but the pathway for leaked fluid becomes longer and more difficult to establish
Solution Approach 1:
The patent divides the leakage detection pathway into segmented components: an inner leakage groove close to the seal for immediate fluid capture, connection grooves that bridge the gap, and an outer leakage groove for collection. This segmentation allows the seal to remain stable under high pressure while still providing an effective pathway for leaked fluid detection.
Data Source
AI summary
A diaphragm compressor having a compressor head with a hydraulic fluid plate having a fluid plate contact plane and a process fluid plate having a process plate contact plane, the plates forming a compression chamber when contact therebetween is established, the compression chamber being divided in an upper chamber and a lower chamber by a multi-layered diaphragm, where a controller is configured for controlling an alternating movement of the multi-layered diaphragm towards the upper and the lower chambers respectively, a process fluid plate seal is positioned in a process fluid seal groove provided in the contact plane, the process fluid plate seal forms a process fluid seal between an upper side of the multi-layered diaphragm and the contact plane, and the process fluid plate includes a process fluid leak groove system fluidly connected to a process fluid plate leakage passage provided in the process fluid plate.