Flushing System for Industrial Fluid Contamination Control
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Solution Overview
Problem
Industrial fluid systems, such as those in injection molding machines and heat exchangers, face contamination issues due to chemical and biological contamination of coolants, leading to inadequate temperature control and reduced process reliability.
Innovation Solution
A flushing system with flexible hoses, a rinsing container, circulation pump, non-return valve, pressure-maintaining valve, and optional dosing system, which includes a Venturi pump and conductivity/pH measurement, is connected to the fluid system for effective cleaning, using air to dissolve residues and a heater for thermal support, and a preservative to maintain system hygiene.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If physical or chemical self-cleaning of coolants is used, then cleaning action is provided, but bacterial deposits are not effectively removed
Solution Approach 1:
The patent changes the physical parameters of the cleaning fluid by heating it to elevated temperatures (e.g., 60-90°C or higher). This temperature parameter change enhances the cleaning effectiveness against bacterial deposits while maintaining system reliability, overcoming the limitation of conventional self-cleaning methods
2Reliability
If expensive cleaning systems are used to ensure reliable temperature control, then temperature control reliability is improved, but system cost increases
Solution Approach 1:
The system enables self-service cleaning where the flushing system uses its own heated cleaning fluid to clean the fluid system components. The circulation pump recirculates the heated cleaning fluid through the fluid system, and the system automatically maintains cleaning effectiveness through continuous or periodic flushing cycles, reducing dependency on expensive external cleaning systems
Solution Approach 2:
By changing the temperature parameter of the cleaning fluid to elevated levels, the patent achieves effective bacterial deposit removal and temperature control reliability using a relatively simple heating system rather than complex expensive cleaning equipment
3Reliability
If continuous flushing is performed to maintain hygiene, then system hygiene is improved, but energy consumption increases
Solution Approach 1:
The patent implements periodic flushing cycles where the circulation pump operates intermittently rather than continuously. The system can switch between flushing mode and normal operation mode, maintaining system hygiene through regular cleaning cycles while reducing energy consumption during normal operation. The heated cleaning fluid retains its cleaning effectiveness across multiple circulation cycles
Solution Approach 2:
The cleaning fluid is heated once and then recirculated multiple times through the fluid system, maintaining its elevated temperature and cleaning effectiveness throughout the flushing process. This continuous useful action of the heated cleaning fluid allows for extended flushing operations without repeated heating energy input
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 provides efficient and hygienic cleaning, ensuring reliable temperature control and process efficiency while being economical and environmentally friendly, with the ability to reuse or dispose of the flushing liquid.
Implementation Method 1
a circulation pump (9), which circulates the flushing liquid through the fluid system (20)
Implementation Method 2
There is also the option of providing thermal support to the cleaning process using a heater.
Implementation Method 3
air can advantageously be introduced into the cleaning circuit continuously or in pulses to dissolve crystalline residues in the fluid system
Implementation Method 4
at least one non-return valve and another pressure-maintaining valve
Implementation Method 5
another pressure-maintaining valve, as well as preferably a compressed air supply and a filter installed in the circulation circuit
Data Source
Figure 1
Figure 2
AI summary
The rinsing device has a circulation circuit line, in which a rinsing container (4), a circulation pump (9) and two valves (10) are integrated. The circulation circuit line has two rinsing pipes, whose ends are provided with couplings (28) that are coupled with fluid channels of a fluid system, so that the fluid channels are embedded in the circulation circuit line. A compressed air line of a compressed air source opens in the circulation circuit line. A filter (21) is integrated in the circulation circuit line.