Foam Cleaning Control Using Effluent Sensing for Machine Downtime
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Solution Overview
Problem
Current cleaning systems for machines with intricate internal mechanisms, such as turbine engines, often require unnecessarily long cleaning durations, wasting materials and keeping the machines out of service for extended periods, regardless of their initial cleanliness.
Innovation Solution
A system and method that utilizes sensors to measure characteristics of effluent foam detergent exiting the machine, such as turbidity, conductivity, and contaminant concentration, to determine the optimal cleaning time, automatically adjusting the duration based on these measurements to ensure thorough cleaning while minimizing waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If foam detergent is directed into the machine for a designated period of time to ensure thorough cleaning, then cleaning quality is improved, but cleaning duration increases and machine availability decreases
Solution Approach 1:
The system employs sensors to continuously monitor effluent characteristics (turbidity, conductivity, contaminant concentration) during the cleaning process and feeds this information back to a controller. The controller adjusts the cleaning duration in real-time based on the measured effluent quality, stopping the cleaning process as soon as the cleaning objectives are achieved, thereby eliminating unnecessary extended cleaning times while ensuring thorough cleaning is completed.
2Reliability
If foam detergent is directed into the machine for a longer period to ensure thorough cleaning, then cleaning quality is improved, but foam detergent consumption increases
Solution Approach 1:
The sensor system monitors effluent characteristics in real-time and provides feedback to the controller. When the effluent meets the cleaning objectives (indicated by acceptable turbidity, conductivity, and contaminant concentration levels), the controller automatically stops the foam detergent flow, preventing excessive foam consumption while ensuring that cleaning quality standards are met.
3Reliability
If cleaning duration is extended to ensure thorough cleaning of all internal mechanisms, then cleaning quality is improved, but machine productivity decreases
Solution Approach 1:
The system uses real-time monitoring of effluent characteristics (turbidity, conductivity, contaminant concentration) with sensor feedback to the controller. This enables the cleaning process to be terminated as soon as the cleaning objectives are achieved, rather than following a fixed extended schedule, thereby maximizing machine availability and productivity while ensuring thorough cleaning of all internal mechanisms.
4Reliability
If cleaning duration is extended to ensure thorough cleaning, then cleaning quality is improved, but operational complexity increases due to material waste management
Solution Approach 1:
The sensor feedback system provides objective, real-time data on effluent characteristics (turbidity, conductivity, contaminant concentration), enabling automated control of the cleaning process termination. This eliminates the need for manual assessment and complex operational decision-making, reducing operational complexity while ensuring consistent cleaning quality standards are met.
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 approach reduces the duration of cleaning processes, conserves cleaning materials, and ensures machines are available for use sooner by optimizing the cleaning time based on real-time effluent analysis.
Implementation Method 1
one or more sensors configured to measure one or more of a turbidity of the effluent portion of the foam detergent that exits from inside the machine
Implementation Method 2
one or more sensors configured to measure one or more of a turbidity of the effluent portion of the foam detergent that exits from inside the machine, a salinity of the effluent portion of the foam detergent
Data Source
AI summary
A machine is cleaned by directing a foam detergent into the machine to remove contaminants from inside the machine. An effluent portion of the foam detergent exits from the machine with some of the contaminants. One or more of a turbidity, a salinity, an amount of total dissolved solids, or a concentration of the contaminants in the effluent is measured. A cleaning time period during which the foam detergent is to be directed into the machine is determined based on the turbidity, the salinity, the amount of total dissolved solids, and/or the contaminant concentration that is measured from the effluent. The foam detergent continues to be directed into the machine during the cleaning time period, and the flow of the foam detergent into the machine is terminated on expiration of the time period.