Fluid Container Flushing With Pressure-Drop Leak Shutdown

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Solution Overview

Problem

Existing methods for flushing contaminants from fluid-containing systems, such as transmission and cooling systems, often result in sudden and unintended discharge of cleaning fluid, leading to potential mishaps, equipment damage, and safety risks.

Innovation Solution

The implementation of a rapid leakage detection and control system that utilizes a pressure sensor and programmable logic controller (PLC) to quickly stop the flow of cleaning fluid in case of sudden leakage, thereby minimizing fluid loss and reducing the risk of injury or equipment damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional flushing systems operate at high pressure and high flow rate to effectively remove contaminants, then cleaning effectiveness is improved, but the risk of sudden fluid discharge and potential mishaps increases

Engineering Contradiction:

Improvecleaning effectivenessVSAvoidrisk of sudden fluid discharge

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The system incorporates pressure sensors that continuously monitor fluid pressure and provide feedback to the control system. When abnormal pressure changes indicating potential leakage are detected, the system automatically responds by adjusting or shutting off the pump, creating a closed-loop control system that maintains cleaning effectiveness while preventing hazardous fluid discharge

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system performs preliminary detection of abnormal conditions through pressure sensors before actual leakage occurs. By monitoring pressure changes in advance and triggering preventive shutdown sequences, the system addresses potential hazards before they manifest as actual fluid discharge incidents

Inventive Principle:

Principle #10Preliminary action

2Productivity

If the system operates continuously at high flow rates to maximize flushing efficiency, then contaminant removal speed is improved, but fluid loss during leakage events increases

Engineering Contradiction:

Improvecontaminant removal speedVSAvoidfluid loss during leakage

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

Pressure sensors provide real-time feedback on system conditions, enabling the control system to detect leakage events immediately and shut down the pump. This rapid response minimizes the duration of any leakage event, thereby reducing fluid loss while maintaining high operational efficiency during normal flushing operations

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system is designed to rapidly detect and respond to leakage conditions, rushing through the shutdown sequence as quickly as possible to minimize fluid loss. The high-speed response protocol ensures that any leakage event is terminated almost immediately, reducing overall fluid loss despite continuous high-rate operation

Inventive Principle:

Principle #21Skipping (Rushing through)

3Productivity

If high pressure and temperature are applied to effectively flush contaminants from expensive equipment, then cleaning performance is improved, but the potential damage from mishaps increases

Engineering Contradiction:

Improvecleaning performanceVSAvoidequipment vulnerability to damage

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The system implements protective measures in advance by continuously monitoring pressure and temperature parameters. When abnormal conditions are detected, the system automatically shuts down before a mishap can occur, cushioning the expensive equipment from potential damage while maintaining high cleaning performance during normal operation

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

Solution Approach 2:

Real-time monitoring of pressure and temperature provides continuous feedback to the control system, enabling immediate shutdown responses that protect expensive equipment from potential damage while allowing high-pressure, high-temperature operation for effective contaminant removal during normal flushing cycles

Inventive Principle:

Principle #23Feedback

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 solution significantly reduces the time required to stop a sudden unintended discharge of cleaning fluid, minimizing fluid loss and mitigating the risks of injury and equipment damage, thus enhancing safety and operational efficiency.

Implementation Method 1

a pressure sensor or pressure switch that detects the level of pressure in hose 302

Methodology Applied

Scientific EffectPressure detection: Pressure Drop

Implementation Method 2

PLC could be programmed to command the pump to stop in the event of a sudden excessive leakage event

Methodology Applied

Scientific EffectAutomated control response: Feedback

Data Source

PatentUS12305746B2Method and apparatus for flushing contaminants from a container of fluids

Publication Date: 2025.05.20 HANSEN DENNIS B

AI summary

A contaminant-flushing machine for removing contaminants from a container, such as an engine transmission, air-conditioner coil, or transmission cooler, which includes hoses for coupling to the transmission cooler and a pump for circulating fluid through the hoses and the transmission cooler, the flushing machine being configured to terminate all circulating of fluid when a pressure drop is detected during times when the fluid is circulating only in the primary flow direction, but not when the flow direction is being reversed.