Flow Tank Aperture Design for Uniform Cleaning Medium Distribution
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Solution Overview
Problem
Phase flow tanks used in the cleaning and rinsing of high precision articles like hard disc drives experience 'dead zones' due to turbulent flow, leading to particle retention and the need for frequent medium replacement, resulting in wastage and capacity loss.
Innovation Solution
A cleaning system with a flow control plate having apertures arranged such that the total outlet area is inversely proportional to the tank's depth, ensuring a uniform outlet flow rate independent of depth, minimizing turbulence and potentially achieving laminar flow, thereby reducing particle retention and the need for frequent medium replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional phase flow tank is used with standard outlet configuration, then the tank can process cleaning medium through the wash area, but dead zones and eddies form due to turbulent flow causing particle retention
Solution Approach 1:
The outlet is segmented into multiple apertures distributed across the flow control plate rather than using a single outlet. This segmentation distributes the flow across many small openings, reducing turbulence and preventing dead zones while maintaining effective particle removal through the cleaning medium
Solution Approach 2:
The aperture distribution is non-uniform, with aperture area concentrated near the top of the plate where pressure head is least, and less aperture area at the bottom where pressure head is greater. This local variation in aperture quality creates uniform flow distribution throughout the wash area, eliminating dead zones and improving particle removal effectiveness
2Reliability
If the rinsing medium is frequently replaced to avoid cross contamination, then particle retention is reduced, but significant wastage of rinsing medium occurs and tank capacity is lost
Solution Approach 1:
The flow control plate design enables continuous effective operation of the rinsing medium without requiring frequent replacement. By eliminating dead zones and ensuring uniform flow distribution, the cleaning medium maintains its effectiveness throughout the wash area for extended periods, allowing continuous processing and reducing both medium wastage and tank downtime
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 system effectively minimizes turbulence and particle retention, allowing for consistent flow rates and reduced medium wastage by maintaining a uniform flow rate throughout the tank, enhancing the cleaning process efficiency and reducing cross-contamination.
Implementation Method 1
there tends to be 'dead zones' within the tank through eddies and other features of discontinuous turbulent flow
Implementation Method 2
achieve laminar flow within the wash are of the tank and so avoid the difficulties associated with turbulent flow
Implementation Method 3
having most of the aperture area concentrated near the top of the plate, where the pressure head is least, and less at the bottom where the pressure head is more
Data Source
AI summary
A cleaning system comprising a tank having a wash area arranged to receive an article for cleaning; an inlet assembly mounted to a first end of the tank, through which a cleaning medium flows into the wash area; an outlet assembly having a flow control plate mounted to a second end of the tank; the flow control plate having a plurality of apertures and arranged such that the cleaning medium flows from the wash area through the apertures; the flow control plate arranged such that a total outlet area of the tank is equal to a sum of areas of the apertures; wherein the proportion of the total outlet area about the flow control plate is inversely proportional to a depth of the tank.