Filter Assembly Test Aerosol Generator Mixing Chamber
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Solution Overview
Problem
Current methods for determining the degree of separation or conducting leak tests in filter arrangements for aerosol and dust separation from gas volume flows are costly and energy-intensive due to the high demand for compressed air, and there is a lack of even mixing between aerosol and air flows.
Innovation Solution
A method involving a mixing chamber where the first mixed volume flow and air volume flow are mixed with opposite or identical flow directions, and a swirl device at the inflow or outflow end to ensure even distribution, reducing the need for expensive compressed air by diluting the aerosol mixture in two stages, resulting in a more economical and effective test aerosol generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If compressed air is used to generate test aerosol in large volume flows, then the aerosol can be atomized into fine particles and sufficient volume flow for testing can be provided, but the cost and energy consumption increase significantly due to high demand for compressed air and drying requirements
Solution Approach 1:
The aerosol generation system is segmented into multiple nozzles arranged in a matrix pattern, where each nozzle generates a portion of the required aerosol volume flow. This segmentation allows the system to achieve high total volume flow without requiring a single high-power compressed air source, thereby reducing energy consumption and cost while maintaining sufficient aerosol generation capacity
Solution Approach 2:
Instead of using one large compressed air system, the patent uses multiple smaller nozzle units that replicate the aerosol generation function. Each nozzle is a simplified copy of the aerosol generation mechanism, and their combined output achieves the required total volume flow at lower energy cost and without the need for expensive drying systems
2Quantity of substance
If aerosol is diluted using two diluter sections connected in series, then the aerosol concentration can be reduced for testing, but it remains unclear whether there is an even mixture of aerosol and fresh air
Solution Approach 1:
The patent employs curved or angled nozzle arrangements and optimized flow paths that promote turbulent mixing and radial distribution of aerosol with fresh air. The geometric configuration of the nozzle matrix and mixing chamber creates swirling flow patterns that enhance mixing uniformity, ensuring even distribution of aerosol particles throughout the diluted volume flow
Solution Approach 2:
The patent transitions from linear or simple series dilution to a two-dimensional matrix arrangement of nozzles. This spatial distribution in multiple dimensions allows fresh air to mix with aerosol from multiple directions simultaneously, creating more uniform mixing compared to sequential single-dimension dilution approaches
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 approach allows for the production of a high-quality test aerosol with a mixing ratio greater than 10:1, significantly reducing energy consumption and costs while ensuring even aerosol distribution, thereby enhancing the efficiency and cost-effectiveness of the test process.
Implementation Method 1
the air volume flow being mixed with the first mixed volume flow before mixing an inflow-side end of the mixing chamber and/or the second mixed volume flow is/are guided through a swirl device at a downstream end of the mixing chamber
Implementation Method 2
compressed air with a pressure level between approx. 1 bar and 2 bar is used to ensure that the aerosol is atomized into the finest particles
Data Source
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AI summary
The method involves providing test aerosol in a crude gas flow in a flow direction viewed before a filter element (9) via a feeding device (16). A number of particles and/or a concentration of the particles in a clean gas flow is determined in the flow direction viewed behind the filter element. A mixed volume flow of the test aerosol and compressed air are generated by an aerosol generator (37). The mixed volume flow is mixed with an air volume flow to form thin mixed volume flow. The mixed volume flow and compressed air are supplied to the feeding device. An independent claim is also included for a device for determining a separation level and/or carrying out a leak test in a filter assembly to separate aerosol and dust in gas volume flow.