Filtration-Free Liquid Sampling for Particulate-Laden Textile Washers
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Solution Overview
Problem
Commercial textile washers face challenges in processing high volumes of soiled textiles due to varying soil levels, leading to inconsistent chemical usage, which can result in excessive cleaning costs or inadequate sanitation. Additionally, existing liquid sampling systems are prone to plugging due to solid materials in the wash liquids, making it difficult to extract and analyze samples effectively.
Innovation Solution
A liquid sampling system that uses a sensor housing and liquid conveyance device with bidirectional flow, employing a motive element like a piston or flexible membrane to draw and expel liquid samples without passing through a screen, thereby preventing plugging and ensuring thorough analysis and purging of solid materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a screen is placed in the sample extraction device to filter solid materials, then the liquid sample can be filtered, but the screen pores will plug with solid material over time, rendering the device inoperable
Solution Approach 1:
The patent removes the screen component entirely from the sample extraction device. Instead of filtering solids through a screen, the system extracts liquid samples directly through an opening in the washer drum, allowing solids to remain in the wash water while enabling continuous operation without screen plugging issues
Solution Approach 2:
The patent introduces a liquid conveyance device as an intermediary component that uses vacuum pressure to draw liquid samples through the opening in the washer drum. This mediator enables sample extraction without requiring direct contact between solids and the extraction mechanism, preventing plugging while maintaining reliability
2Reliability
If chemical additives are preprogrammed in high quantities to cover heavily contaminated articles, then sanitation is ensured, but most wash cycles will overdose on chemical additive, resulting in excessive cleaning cost
Solution Approach 1:
The patent implements a feedback system where liquid samples are continuously extracted from the washer during the wash cycle and analyzed by sensors. The sensor readings about chemical concentrations and soil levels are fed back to the controller, which adjusts chemical additive delivery in real-time, preventing both overdose and underdose scenarios
Solution Approach 2:
The system dynamically changes the parameters of chemical additive concentration and flow rate based on real-time sensor analysis of liquid samples. Instead of using fixed preprogrammed quantities, the controller adjusts these parameters continuously according to the actual soil level and chemical concentration detected in the wash water
3Loss of substance
If chemical additives are preprogrammed in low quantities to reduce cost, then cleaning cost is reduced, but the article may not be properly cleaned and sanitized/disinfected
Solution Approach 1:
The feedback mechanism continuously monitors chemical concentrations and soil levels through sensor analysis of extracted liquid samples. When sensors detect insufficient chemical concentration or high soil levels, the controller automatically increases additive delivery, ensuring proper sanitation while minimizing chemical usage by only adding what is needed
Solution Approach 2:
The system enables the washing process to self-regulate chemical usage based on actual conditions. The sensors and controller work together to allow the system to automatically adjust chemical additive delivery without external intervention, ensuring both cost efficiency and cleaning effectiveness through real-time self-monitoring and self-adjustment
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 system allows for efficient extraction and analysis of liquid samples from textile washers, preventing plugging and ensuring accurate chemical monitoring, thereby optimizing cleaning processes and reducing costs by ensuring appropriate chemical usage based on soil levels.
Implementation Method 1
The liquid conveyance device may generate a vacuum pressure to draw liquid from the larger source to the liquid conveyance device
Implementation Method 2
The liquid conveyance device may also generate a positive pressure to expel the liquid drawn toward the conveyance device back away from the conveyance device
Data Source
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AI summary
A filtration-free liquid sampling system (30) may be used to extract particulate or debris-containing liquid samples that may otherwise plug a filter over its service life. For example, such a system (30) may be used to extract liquid sample from an industrial textile washer t(20) o monitor and/or validate the quality of wash conditions within the washer (20). In some examples, the system (30) includes a pump (34) that creates a vacuum on a backstroke, drawing liquid into a sensor housing positioned between the pump (34) and the washer (20). After holding the liquid in the sensor housing (32) long enough to measure its properties, the pump (34) can be driven in a reverse stroke to pressurize the contents in the sensor housing (32) and force the liquid back into the washer (20). This vacuum fill / pressure purge can keep the sensor housing (32) free of debris.