Shell-and-Tube Heat Exchanger Cleaning With Optical Conduit Mapping

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Solution Overview

Problem

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

Innovation Solution

An automated system using a camera, mechanical cleaning device, and optical sensors to map and clean fluid conduits, employing a robotic arm and controller for precise cleaning operations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual cleaning is performed, then cleaning can be completed, but labor intensity and time consumption increase

Engineering Contradiction:

Improvecleaning efficiencyVSAvoidcleaning time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The cleaning system is designed to autonomously navigate and clean conduits without human intervention. The robotic device independently maps the conduit geometry, positions itself, and executes cleaning operations, allowing the system to serve itself rather than requiring manual operation by technicians.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual mechanical cleaning operations are replaced with an automated robotic system equipped with specialized cleaning tools. The robotic device uses controlled mechanical movements guided by digital mapping and positioning systems, substituting human labor with automated mechanical systems that operate more efficiently and consistently.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If manual cleaning is performed, then cleaning can be completed, but ergonomic risks to technicians increase

Engineering Contradiction:

ImprovesafetyVSAvoidoperator safety

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The robotic cleaning device performs all cleaning operations autonomously within the conduit environment, eliminating the need for human operators to physically enter or closely handle contaminated areas. The system navigates, cleans, and exits without human intervention, ensuring operator safety while maintaining reliable cleaning performance.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The robotic device acts as an intermediary between the operator and the hazardous cleaning environment. It handles the dangerous tasks of navigating confined spaces and removing deposits, serving as a mediator that protects human operators from ergonomic injuries and exposure to contaminants while achieving the cleaning objective.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Extent of automation

If automated cleaning system is implemented, then labor and safety improve, but device complexity increases

Engineering Contradiction:

Improveautomation levelVSAvoidsystem complexity

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The robotic cleaning device is designed as a multi-functional platform that can perform mapping, navigation, positioning, and various cleaning operations through interchangeable tools. This universal design consolidates multiple functions into a single system, managing complexity through integration rather than proliferation of separate devices.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system employs nested functional layers where high-level automation tasks (navigation and cleaning planning) contain lower-level tasks (motor control and sensor processing), which in turn contain basic control loops. This nested architecture manages complexity by organizing functions hierarchically, with each layer building upon the previous one.

Inventive Principle:

Principle #7Nested doll (Nesting)

4Reliability

If frequent cleaning is performed, then heat exchanger efficiency is maintained, but labor and time resources are consumed

Engineering Contradiction:

Improveheat exchanger efficiencyVSAvoidcleaning resource consumption

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The automated system enables heat exchangers to be cleaned efficiently without consuming significant labor or time resources. By operating autonomously, the system can perform maintenance tasks during periods that would otherwise be productive, effectively allowing the heat exchanger maintenance to be self-serviced without impacting overall operational productivity.

Inventive Principle:

Principle #25Self-service

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

Automated cleaning reduces labor and ergonomic risks, enhances efficiency by minimizing manual intervention, and maintains conduit performance by removing mineral deposits effectively.

Implementation Method 1

an optical sensor wherein the optical sensor is capable of returning data that can be used to determine X and Y coordinate of a center point of the fluid conduit

Methodology Applied

Scientific EffectOptical detection: Reflection

Data Source

PatentEP4671667A1Automated shell and tube heat exchanger cleaner

Publication Date: 2025.12.31 INTEL CORP

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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.