Expansion Tank Defect Detection by Burner-On Pressure Averaging
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for detecting a defective diaphragm expansion vessel in a heating circuit with a burner require complete emptying of the vessel, which is inefficient and not continuously monitorable.
Innovation Solution
Calculating a mean pressure value when the burner is switched on and comparing it with a pressure reference value to continuously monitor the vessel's functionality, allowing for early detection of defects without the need for control emptying.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the diaphragm expansion vessel is completely emptied to detect a defect, then the defect detection becomes possible, but the system operation is interrupted and time is lost
Solution Approach 1:
The patent applies preliminary action by continuously monitoring pressure data during normal operation to detect defects before they become critical. The evaluation criterion is calculated in advance based on pressure measurements taken during burner operation, allowing defect detection without interrupting system operation or emptying the expansion vessel.
Solution Approach 2:
The patent replaces the mechanical approach of completely emptying the vessel for inspection with a sensor-based pressure measurement system. By using pressure sensors and evaluating pressure changes during burner operation, the system detects defects through electrical/electronic means rather than mechanical intervention, eliminating the need to stop operation or empty the vessel.
2Productivity
If pressure data is continuously monitored during burner operation, then defect detection becomes possible without emptying the vessel, but additional measurement and calculation steps are required
Solution Approach 1:
The system uses existing pressure sensors already present in the heating system for other purposes (monitoring system pressure) and repurposes them for defect detection. The same sensors that monitor general system pressure are used to collect data for calculating the evaluation criterion, eliminating the need for additional dedicated sensors or complex measurement equipment.
Solution Approach 2:
The pressure sensor serves multiple functions: it monitors general system pressure for normal operation and simultaneously provides data for defect detection by calculating pressure changes during burner operation. The evaluation criterion calculation uses the same pressure data that is already being collected for system monitoring, making the defect detection system multi-functional and avoiding additional hardware 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
Enables continuous monitoring of the diaphragm expansion vessel's proper functioning, reducing the risk of safety hazards by detecting defects without the need for complete vessel emptying, and providing timely alerts for maintenance.
Implementation Method 1
The pressure in the heating circuit rises and falls, with the current pressure data being able to be determined by means of a corresponding pressure sensor
Implementation Method 2
The membrane expansion vessel consists in a known manner of two volumes between which an elastic membrane is arranged
Implementation Method 3
a temperature change in the heating circuit medium immediately leads to a pressure change in the closed heating circuit 2
Implementation Method 4
the other with gas, the second volume being sealed off from the outside and acting together with the membrane like a gas spring for the water volume
Data Source
Figure 1~3
AI summary
The method involves controllably switching on and off of a burner (3), and detecting actual pressure data of a pressure sensor (4) by a heating circuit (2). An integrative pressurized average value is formed from the detected actual pressure data during switching on of the burner. The pressurized average value and a pressurized reference value are compared with each other from a temperature reference value of a heating boiler (5) or from an operating time-reference value of the burner, where the heating boiler is connected to the heating circuit.