Exhaust Gas Filter Sensor for Fill Level Detection
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Solution Overview
Problem
Existing technologies fail to accurately determine the quantity of separated solid substances and particles during the separation process in additive manufacturing, particularly in selective laser beam sintering or melting, posing a hazard due to their small particle sizes and potential chemical reactivity.
Innovation Solution
A device with a filter element and a collection container equipped with sensors connected to an electronic evaluation and control unit for determining the fill level of deposited substances, allowing for sequential or continuous monitoring and control, including non-contact detection and mechanical positioning for precise measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If filtration of exhaust gas is performed to separate particles and substances, then the hazard potential is reduced, but the quantity of separated solid substances cannot be accurately determined
Solution Approach 1:
The patent replaces manual estimation or indirect measurement methods with direct electronic sensing. Sensors (optical, capacitive, inductive, or contact-based) are integrated into the collection container to automatically detect and signal when maximum fill level is reached, providing accurate quantity determination without relying on visual inspection or manual measurement.
Solution Approach 2:
The patent implements a feedback mechanism where sensors continuously or periodically monitor the fill level of solid substances in the collection container. When the maximum fill level is detected, the system provides immediate feedback through signals to the control unit, which can then trigger alerts or shutdown procedures, ensuring accurate and timely quantity information is available.
2Measurement precision
If sensors are placed in the collection container to detect fill level, then quantity determination is improved, but device complexity increases
Solution Approach 1:
The patent extracts the sensing function from complex external measurement systems and integrates simple sensors directly into the collection container structure. This allows fill level detection to be performed at the point of need using minimal components, reducing overall system complexity while maintaining measurement precision.
Solution Approach 2:
The collection container is designed to be self-monitoring through integrated sensors that automatically detect fill level without requiring external intervention. The sensor system serves itself by providing direct feedback to the control unit, eliminating the need for manual checking or complex external measurement apparatus.
3Reliability
If continuous monitoring is implemented to determine fill level, then safety is improved, but energy consumption increases
Solution Approach 1:
The patent implements periodic monitoring where sensors check the fill level at predetermined time intervals rather than continuously. This approach maintains safety by regularly detecting when maximum fill level is reached while significantly reducing energy consumption compared to continuous monitoring. The control unit can be programmed to check at appropriate intervals based on operational requirements.
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 accurate and reliable determination of the fill level, triggering alerts for container replacement and system shutdown to prevent hazardous conditions, ensuring safe operation and minimizing chemical reactions.
Implementation Method 1
solid substances and particles deposited on the bottom of the collection container due to the force of gravity
Implementation Method 2
The mechanical device can have a displacement sensor with which the respective fill level can be determined
Data Source
Figure 1
AI summary
The invention relates to a device for extracting and separating substances and particles from exhaust gases, which are generated particularly during the production of three-dimensional components using selective laser sintering or laser melting. At least one filter element for separating substances and particles is arranged in a housing. A vacuum generator draws the exhaust gas containing the unwanted substances and particles through the at least one filter element, and the substances and particles are deposited in a collection container. At least one sensor is located in and/or on the collection container to determine the fill level of solid substances and particles that have settled at the bottom of the container due to gravity. The at least one sensor is connected to an electronic evaluation and control unit and an optical and/or acoustic display unit.