Heat Exchanger Tube Cleaner With AI Conduit Mapping

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Solution Overview

Problem

Chiller conduits require frequent manual cleaning, which is labor-intensive and poses ergonomic risks, and the process is inefficient, with mineral deposits reducing heat exchanger efficiency over time.

Innovation Solution

A robotic system with a camera, mechanical cleaning device, and optical sensors automates the cleaning process, using a controller and AI to map and clean fluid conduits, employing a brush or scrub pad to remove mineral deposits.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual cleaning is performed, then cleaning can be accomplished, but labor intensity and ergonomic risks increase

Engineering Contradiction:

Improveease of cleaning operationVSAvoidcomplexity of cleaning system

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The cleaning device is self-propelled through the conduit using a propeller that generates thrust, eliminating the need for external mechanical pushing systems. The device autonomously navigates the conduit while performing cleaning operations, reducing the mechanical complexity required for propulsion while maintaining effective cleaning capability.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces manual mechanical cleaning operations with an automated device that uses electrical motors for propulsion and cleaning functions. The propeller-driven movement and motorized cleaning mechanisms substitute human physical labor, reducing ergonomic risks while managing system complexity through electronic control.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If cleaning frequency is increased, then heat exchanger efficiency is maintained, but labor costs and time consumption increase

Engineering Contradiction:

Improvecleaning efficiencyVSAvoidtime required for cleaning

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The cleaning device continuously engages with the conduit wall during its entire traversal, maintaining constant cleaning action from entry to exit. The rotating cleaning elements remain in contact with the conduit surface throughout the cleaning path, ensuring uninterrupted removal of deposits without requiring multiple passes or停顿, thereby reducing total cleaning time while maintaining effectiveness.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The patent introduces a fluid delivery system that provides cleaning fluid or chemical agents as an intermediary to enhance the mechanical cleaning action. This fluid medium assists in loosening and removing deposits, increasing cleaning efficiency and allowing for faster treatment of heavily fouled conduits, thereby reducing overall cleaning time.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If cleaning instrument size is increased, then cleaning effectiveness improves, but difficulty of insertion and navigation increases

Engineering Contradiction:

Improvecleaning effectivenessVSAvoidease of insertion

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The cleaning device is divided into distinct functional segments: a propulsion section with the propeller, a cleaning section with rotating elements, and a fluid delivery section. This segmentation allows each component to be optimized independently, with the cleaning elements positioned at the leading edge to address deposits before they harden, maintaining effectiveness while managing overall device size for easy insertion.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cleaning device incorporates flexible or adjustable components that can adapt to the conduit geometry. The cleaning elements are positioned to engage the conduit wall dynamically as the device moves through bends or variations in the conduit path, ensuring reliable cleaning contact without requiring a rigid, oversized structure that would be difficult to insert.

Inventive Principle:

Principle #15Dynamics

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 significantly reduces manual labor, enhances cleaning efficiency, and maintains heat exchanger performance by effectively removing mineral deposits, thereby improving thermal management.

Implementation Method 1

a propeller positioned at a rearwardmost portion of the housing and configured to generate thrust to move the housing forward along the conduit

Methodology Applied

Scientific EffectThrust: Jet

Implementation Method 2

employing a brush or scrub pad to remove mineral deposits

Methodology Applied

Scientific EffectMechanical abrasion: Abrasion

Data Source

PatentUS20260002744A1Automated shell and tube heat exchanger cleaner

Publication Date: 2026.01.01 INTEL CORP

AI summary

Systems for cleaning bundles of fluid conduits include mechanisms for detecting and mapping fluid conduit locations as well as moving a cleaning device to the detected and mapped fluid conduit locations. Systems can clean the fluid conduits in a fluid conduit bundle, such as the fluid conduits of a heat exchanger.