Dust Extractor Fill-Level Sensing in Dust Explosion Zones
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Solution Overview
Problem
Existing dedusting devices face challenges in accurately monitoring the fill level of collection containers in dust explosion zones due to imprecision in visual checks and errors from optical sensors, and high costs of ultrasonic sensors.
Innovation Solution
A conventional level sensor is protected with a cover that shields its blind area from contaminants and prevents fogging, allowing it to function accurately in dust explosion zones by encasing the sensor in a steel housing and using a protective sleeve to shield electrical connections and the adjustment range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If an optical sensor is used to monitor fill level in the dust zone, then the monitoring can be performed remotely, but the sensor generates error messages due to airborne dust particles causing inaccurate measurements
Solution Approach 1:
A transparent protective cover is introduced as an intermediary element between the optical sensor and the dust-filled environment. This cover allows light to pass through for sensing while physically blocking dust particles from reaching the sensor lens, thus maintaining both remote monitoring capability and measurement accuracy without requiring the sensor to be directly exposed to the dust zone
Solution Approach 2:
Instead of using expensive specialized sensors designed for dust zones, the invention employs a conventional optical sensor combined with a simple transparent protective cover. This approach replaces costly specialized equipment with affordable off-the-shelf components, achieving reliable operation in dust environments without significant investment
2Reliability
If a conventional level sensor is used in the Staubex zone 21, then the fill level can be monitored, but the sensor is very expensive and economically unviable
Solution Approach 1:
The invention replaces expensive specialized Staubex zone sensors with conventional, inexpensive optical level sensors. By adding a simple transparent protective cover, the system achieves reliable fill level monitoring in dust zones using affordable off-the-shelf components, making the solution economically viable for widespread implementation
Solution Approach 2:
The invention creates a protected micro-environment around the sensor that copies the safety characteristics of specialized dust-zone sensors. The transparent cover replicates the protective function of expensive specialized sensors while allowing the use of cheaper conventional sensors, effectively copying the desired performance at lower cost
3Ease of manufacture
If visual inspection through a viewing window is used to monitor fill level, then no additional sensors are needed, but the method is complex and inaccurate
Solution Approach 1:
The invention replaces manual visual inspection with an automated optical sensor system. The transparent protective cover enables the optical sensor to accurately measure fill level automatically without requiring human intervention or complex viewing window mechanisms, thereby improving both measurement precision and operational simplicity
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 significantly reduces error messages and ensures precise fill level monitoring, enabling the sensor to operate effectively in dust explosion zones without malfunctions.
Implementation Method 1
the at least one sensor is designed as an ultrasonic sensor
Data Source
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Figure 5~6
AI summary
The invention relates to a dust removal device (1) for separating contaminants from an airflow, in particular chips and dust, comprising at least: an air inlet, a fan for drawing in and blowing out the airflow, a filter arrangement for cleaning the airflow, which has a plurality of filters (4), at least one collection container (5) for collecting the contaminants filtered from the airflow, at least one sensor which monitors a fill level of the at least one collection container (5), and an air outlet, wherein the at least one sensor has a channel-like cover (8) which protects the blind area of the at least one sensor from the ingress of contaminants and prevents the sensor lens (14) from fogging with contaminants, wherein the at least one sensor is arranged in the dust area of the at least one collection container (5).