Modular Flame Detector Filter Module Adaptability
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Solution Overview
Problem
Existing flame detectors in oil refineries and chemical plants are typically sold in fixed configurations, limiting their adaptability to detect different types of fires, as the wavelength filters are permanently affixed and require separate models for hydrocarbon and non-hydrocarbon fires.
Innovation Solution
A modular flame detector design featuring interchangeable filter modules that can be easily swapped, allowing for customization to detect various fire types by changing the set of filters, which can be factory or field-installed, and secured using fasteners or snap-fit mechanisms, compatible with broadband infrared or UV detectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If wavelength filters are permanently affixed to the detector, then the detector structure is simple and reliable, but the detector cannot be easily adapted to detect different types of fires
Solution Approach 1:
The filter assembly is segmented into a separate, removable module that can be independently exchanged. The filter holder is designed as a distinct component from the detector body, allowing filters to be segmented and replaced without affecting the entire detector structure.
Solution Approach 2:
A single detector body is designed to accommodate multiple types of filters through a universal filter holder interface. The detector can perform multiple detection functions (hydrocarbon, non-hydrocarbon, dual-mode) by simply changing the filter module, making the base detector universal rather than specialized.
2Adaptability or versatility
If multiple fixed configuration detectors are manufactured for different fire types, then each detector is optimized for its specific function, but inventory complexity and cost increase
Solution Approach 1:
One detector model with a universal filter holder can replace multiple specialized detector models. The detector body remains unchanged while the filter modules provide the specialization, reducing the number of detector models from several to one base model plus multiple filter attachments.
Solution Approach 2:
The fire-type-specific filtering functionality is extracted from the detector body and placed into separate, interchangeable filter modules. This allows the core detector to be standardized while the variable filtering components are taken out as independent exchangeable units.
3Ease of operation
If filters are permanently installed in the detector, then the detector is ready for immediate use, but changing filters requires complex disassembly or specialized tools
Solution Approach 1:
The filter assembly is segmented into a pre-assembled module containing the filter and holder, which can be quickly exchanged as a single unit. This segmentation allows the filter to be replaced without disassembling the entire detector or handling individual filter components.
Solution Approach 2:
The filter holder is designed with dynamic, movable components such as spring-loaded clips or bayonet connectors that allow quick insertion and removal. The mechanical connection transitions from static/permanent to dynamic/reversible, enabling rapid filter changes without specialized tools.
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 flexible and efficient detection of different fire types without the need for multiple fixed configurations, reducing inventory and allowing for quick adaptation to changing environments, while maintaining reliability through explosion-proof housings and wireless or wired communication with monitoring systems.
Implementation Method 1
The detectors are tuned to either of these two fire types by the selection of particular wavelength filters that are placed in front of an infrared radiation sensor, such as, for example, a pyroelectric sensor.
Implementation Method 2
infrared radiation sensor
Implementation Method 3
particular wavelength filters that are placed in front of an infrared radiation sensor. Infrared filters usually pass wavelengths of 2-6 microns.
Data Source
Figure 1A
Figure 1B
Figure 2A
AI summary
A flame detector includes a sensor module, which carries a plurality of pyroelectric sensors, and a filter module which carries a plurality of replaceable filters with one filter being associated with each sensor. The modules are coupled together and carried in an exterior housing. A cover can overlay the filters to retain them in predetermined positions relative to the respective sensors.