Flame Arrestor Cross-Sectional Profile for Process Transmitter
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Solution Overview
Problem
Conventional flame-proofing configurations for industrial process transmitters are costly, require expensive electrical discharge machining (EDM), and result in dirty, difficult-to-clean slag layers that can interfere with sensor operation, necessitating an improvement in flame-proof paths that are cleaner, smaller, and less expensive.
Innovation Solution
A flame arrestor with a different cross-sectional profile is integrated into the passageway of the transmitter, allowing for conventional machining techniques and improved manufacturability, increasing the cross-sectional area and perimeter of the flame-quenching path while maintaining effective flame-proofing, thereby reducing the overall size and cost of the transmitter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional flame-proofing configurations are used with long and narrow cylindrical paths, then flame-proofing capability is improved, but the thickness of the flange or plug increases beyond structural requirements
Solution Approach 1:
The flame arrestor divides the single large passageway into multiple smaller sub-passageways. This segmentation allows each sub-passageway to provide flame quenching while the collective arrangement maintains adequate flow capacity, resolving the contradiction between flame-proofing capability and passageway size.
Solution Approach 2:
The flame arrestor is positioned within the existing passageway structure, nesting the flame-quenching function inside the transmitter housing. This allows the flame-proofing path to be integrated without significantly increasing the overall thickness of the flange or plug beyond structural requirements.
2Manufacturing precision
If electrical discharge machining (EDM) is used to machine small diameter paths through thick slabs, then flame-proofing precision is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The flame arrestor is designed as a separate, replaceable component that can be manufactured using conventional, cost-effective machining processes. This disposable-like approach allows for simpler manufacturing compared to machining the flame path directly into the thick slab, reducing both cost and complexity while maintaining precision.
Solution Approach 2:
By separating the flame arrestor function into a distinct component, the manufacturing process is divided into simpler steps: machining the passageway and separately manufacturing the flame arrestor. This segmentation allows each part to be made with appropriate precision using suitable processes, avoiding the need for expensive EDM on thick slabs.
3Reliability
If EDM processes are used to create flame-proof paths, then flame-proofing capability is improved, but slag layer contamination increases which interferes with sensor operation
Solution Approach 1:
The flame arrestor component is extracted as a separate part that can be manufactured and cleaned independently before installation. This removes the contamination problem from the main transmitter body, as the flame arrestor can be thoroughly cleaned of any machining residues before being installed in the clean hydraulic environment.
Solution Approach 2:
The flame arrestor is designed as a replaceable component that can be manufactured using conventional machining processes that produce minimal contamination. If contamination does occur, the entire flame arrestor can be removed and replaced rather than requiring cleaning of the critical hydraulic passageway, effectively managing the contamination issue.
4Reliability
If the passageway cross-sectional area is reduced for flame quenching, then flame-proofing capability is improved, but hydraulic fluid flow capacity decreases
Solution Approach 1:
The flame arrestor creates multiple small flow paths within its structure. While each individual path is small for effective flame quenching, the collective cross-sectional area of all paths combined maintains adequate hydraulic fluid flow capacity. This segmentation resolves the contradiction by providing both flame quenching surface area and flow capacity.
Solution Approach 2:
The flame arrestor structure provides different qualities in different regions: the internal surfaces of the small sub-passageways provide high surface-area-to-volume ratio for flame quenching, while the overall arrangement of multiple paths maintains adequate flow capacity. This local differentiation of quality resolves the contradiction between flame quenching and flow capacity.
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 enhances the manufacturability and performance of flame-proofing, reduces the risk of contamination, and improves the responsiveness and reliability of the transmitter by increasing the surface area for flame quenching and hydraulic fluid flow, while maintaining effective flame-proofing capabilities.
Implementation Method 1
it is desirable to ensure that all passageways connecting the interior of the transmitter to the exterior environment be configured to extinguish or quench flames traveling through the passageways
Data Source
AI summary
A process transmitter for sensing a process variable includes a transmitter housing, a sensor, transmitter circuitry, a passageway and a flame arrestor. The transmitter housing has an interior. The sensor is disposed within the interior, senses a process variable of an industrial process and generates a sensor signal. The transmitter circuitry is disposed within the interior and connects to the sensor. The passageway is in communication with the sensor and extends through the interior of the transmitter housing. The passageway has a first cross-sectional profile. The flame arrestor is positioned in the passageway. The flame arrestor has a second cross-sectional profile different from the first cross-sectional profile. The flame arrestor produces a path in an interior of the passageway having a smaller cross-sectional area than that of the first cross-sectional profile of the passageway.