Filter Hose Defect Detection via Exhaust Gas Load Monitoring
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Solution Overview
Problem
Industrial filter devices face challenges in detecting deteriorating filter performance before a filter hose fails, leading to costly and time-consuming troubleshooting and potential non-compliance with environmental regulations due to the complexity of monitoring large systems and the inability to identify failing filter groups in a timely manner.
Innovation Solution
A monitoring method that determines the state of each filter group by analyzing the particle load in the exhaust gas during cleaning operations in relation to other filter groups, using a monitoring device to integrate and compare load data over specific time intervals, allowing for early detection of performance degradation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If filter bags are monitored individually to detect performance degradation early, then detection precision improves, but device complexity increases due to the large number of filter bags
Solution Approach 1:
The patent combines multiple filter bags into filter groups (first filter groups and second filter groups) and monitors each group collectively rather than individual filter bags. This merging approach reduces the number of monitoring units from thousands of individual filter bags to a manageable number of filter groups, thereby reducing device complexity while maintaining adequate detection capability for performance degradation
Solution Approach 2:
The patent segments the large filter system into multiple filter groups (first filter groups with first filter bags and second filter groups with second filter bags) that can be monitored separately. This segmentation allows the monitoring system to handle the complexity by dividing it into smaller, manageable units, each with its own monitoring capabilities
2Reliability
If all filter bags are replaced preemptively to ensure compliance, then reliability improves, but loss of substance increases due to unnecessary replacement
Solution Approach 1:
The patent implements a feedback-based monitoring system that continuously measures particle concentration in exhaust gas and provides information about filter group performance. This feedback enables condition-based maintenance decisions, allowing filter bags to be replaced only when actually needed rather than following a predetermined schedule, thus reducing unnecessary replacement while ensuring compliance
Solution Approach 2:
The patent performs preliminary detection of performance degradation by monitoring particle concentrations before complete filter failure occurs. This preliminary action allows maintenance to be scheduled at optimal times based on actual filter condition rather than arbitrary preemptive replacement, reducing unnecessary material loss while maintaining reliability
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 early identification of filter group performance issues, reducing the need for preemptive replacement of all filter bags and allowing targeted maintenance, thus minimizing downtime and costs while ensuring compliance with environmental regulations.
Implementation Method 1
analyzing the particle load in the exhaust gas during cleaning operations
Implementation Method 2
the exhaust gas enters the filter bags of the respective first filter group on an air supply side and out of the filter bags of the respective first filter group on an exhaust air side
Implementation Method 3
the filter bags of the respective first filter group on the exhaust air side via a first valve assigned to the respective first filter group are subjected to a cleaning gas, so that the filter cake accumulated on the air supply side of the filter bags of the respective first filter group is detached
Data Source
Figure 1~2
Figure 3~6
Figure 7
AI summary
In normal operation, a filter device (5) filters loaded waste gas (2) in filter groups (8) with filter sleeves (7). In a cleaning operation, a cleaning gas (12) is applied to a respective filter group (8) on the waste air side (10) via an associated valve (13) such that the filter cake (11) detaches from the incoming air side (9) of the filter sleeves (7). A sensor device (16) arranged in the waste gas channel (6) detects a loading (B) of the waste gas (2) caused by the cleaning operation of each filter group (8). A monitoring device (17) records the generated loading (B) of the waste gas (2). It determines a respective state for every filter group (8), on the basis of the loading (B) caused by the cleaning operation of each filter group (8) in connection with the loading (B) caused by the cleaning operation of at least one other filter group (8).