Filter Valve Regulates Backflushing Discharge Rate
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Solution Overview
Problem
Existing filter devices for lubricating oil require high energy consumption due to continuous backflushing, which increases pump capacity and energy usage, and are not energy-efficient.
Innovation Solution
A filter device with a valve device acting as a pressure compensator that regulates the discharge rate of backflushing fluid based on differential pressure, reducing the backflushing volume and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If continuous backflushing is used to clean the filter, then the filter maintains cleaning capability, but the pump capacity and energy consumption increase
Solution Approach 1:
The backflushing operation is switched from continuous to periodic/discontinuous mode. The control system activates the backflushing pump only when the filter reaches a predetermined contamination level (indicated by pressure differential), and deactivates it when the filter is sufficiently cleaned. This periodic operation maintains filter effectiveness while dramatically reducing overall pump capacity requirements and energy consumption.
Solution Approach 2:
The system incorporates a control system that continuously monitors the pressure differential across the filter element. When the pressure differential reaches a predetermined threshold, the control system activates the backflushing pump. After backflushing, the pressure differential decreases, and the control system deactivates the pump. This feedback mechanism ensures optimal cleaning timing and prevents unnecessary pump operation.
2Reliability
If continuous backflushing is used to maintain filter performance, then the filter remains effective, but the drive motors require higher power and have reduced service life
Solution Approach 1:
The backflushing pump and drive motors operate periodically rather than continuously. The control system activates the motors only when backflushing is required, allowing them to cool down and reducing cumulative wear. This extends motor service life while maintaining filter performance through timely cleaning interventions.
Solution Approach 2:
The system uses the filter's own contamination level (indicated by pressure differential) to trigger self-cleaning. The control system automatically activates backflushing when the filter reaches its contamination threshold, eliminating the need for external monitoring or manual intervention to determine when cleaning is needed.
3Reliability
If independent backflushing pumps are used for each filter, then the cleaning operation is effective, but the monitoring effort and system complexity increase
Solution Approach 1:
The control system is designed to manage multiple filters universally. A single control unit can monitor and control backflushing operations for multiple filter elements, using common pressure differential sensors and control logic. This multi-functional approach reduces the need for separate independent control systems for each filter, thereby reducing overall system complexity and monitoring effort.
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
The solution minimizes backflushing energy requirements, extends the service life of drive motors, and maintains operational efficiency by adjusting backflushing intensity based on filter contamination levels.
Implementation Method 1
a valve device acting as a pressure compensator that regulates the discharge rate of backflushing fluid based on differential pressure
Data Source
AI summary
A filter device is disclosed comprising a filter which is used to clean a fluid flow of particulate contamination in a specifiable flow direction, having a fluid inlet for supplying an unfiltered medium flow, a fluid outlet for removing a filtrate flow, and a discharge opening for discharging a backflushing fluid produced while backflushing the filter against the specifiable flow direction using a backflushing device, wherein as the particulate contamination being cleaned out of the fluid flow by the filter increases, the differential pressure between the fluid inlet and the fluid outlet increases, characterised in that a valve device is arranged downstream of the discharge opening, viewed in the fluid flow direction, said valve device regulating the discharge rate of backflushing fluid as a function of the differential pressure.