Integrated Flow Pressure Sensor for Explosion Protection
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Solution Overview
Problem
Existing explosion protection systems for electrical apparatuses and machines in hazardous environments are heavy, voluminous, expensive, unreliable, and prone to failure due to dust or paint blockages, requiring multiple local detectors and units for ventilation, which hinders optimal location and reliability.
Innovation Solution
A flow- and pressure sensor system with a built-in relief valve and integrated purge controller that supervises both inlet and outlet of a pressurized enclosure with serial-coupled sub-compartments, eliminating the need for local sensors, optimizing air and energy consumption, and allowing for simultaneous control of multiple enclosures, with features like leak detection and feedback for preventive maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple local detectors and ventilation units are used in known explosion protection systems, then the protection coverage is improved, but the system weight, volume, and cost increase
Solution Approach 1:
The patent combines multiple separate detectors and ventilation units into a single integrated flow- and pressure sensor unit with built-in relief valve. This merging reduces the number of components, decreases system weight and volume, while maintaining comprehensive protection coverage through the unified sensor's ability to monitor both flow and pressure parameters simultaneously.
Solution Approach 2:
The integrated sensor unit performs multiple functions: it detects flow rate, measures pressure, monitors enclosure integrity, and controls ventilation activation. This multi-functionality eliminates the need for separate local detectors and ventilation units, reducing system complexity and weight while ensuring comprehensive explosion protection.
2Reliability
If multiple local detectors and ventilation units are deployed, then the protection coverage is improved, but the system volume increases
Solution Approach 1:
The patent merges multiple separate components (flow sensor, pressure sensor, relief valve, ventilation control) into a single compact integrated unit. This consolidation dramatically reduces the system volume occupied by protection equipment, allowing for more flexible installation locations while maintaining comprehensive monitoring and control capabilities.
Solution Approach 2:
The integrated sensor unit combines multiple detection and control functions in one device, eliminating the need for separate local detectors and ventilation units. This multi-functional design reduces the overall system volume while ensuring complete protection coverage through centralized monitoring of both flow and pressure parameters.
3Ease of manufacture
If relief valve is positioned in conventional locations, then the design is simple, but the valve becomes blocked by dust or paint
Solution Approach 1:
The integrated sensor unit proactively monitors flow and pressure parameters to detect potential blockages before they cause valve failure. The system initiates preventive maintenance actions or alerts operators before dust or paint accumulation completely blocks the relief valve, maintaining reliability while keeping the design relatively simple.
Solution Approach 2:
The flow and pressure sensors provide continuous feedback about the relief valve's operational status. By monitoring changes in flow rate and pressure differential across the valve, the system can detect early signs of blockage and trigger maintenance protocols, preventing complete valve failure while maintaining design simplicity.
4Ease of manufacture
If conventional ventilation control is used, then the system is straightforward to implement, but air consumption is not optimized
Solution Approach 1:
The ventilation control system dynamically adjusts air flow based on real-time measurements from the flow and pressure sensors. Instead of operating at fixed rates, the ventilation units modulate their output according to actual enclosure conditions, optimizing air consumption while maintaining effective purging and protection.
Solution Approach 2:
The integrated sensor unit provides continuous feedback on enclosure pressure and air flow rates, enabling the ventilation control system to optimize air consumption. The system adjusts ventilation output based on measured parameters, reducing wasted air intake while ensuring adequate purging and maintaining positive pressure differential for explosion protection.
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 a cost-effective, reliable, and efficient explosion protection solution by reducing downtime, optimizing air consumption, and enabling preventive maintenance, while ensuring safe operation and reduced potential for uncontrolled shutdowns.
Implementation Method 1
A flow- and pressure sensor system with a built-in relief valve and integrated purge controller that supervises both inlet and outlet of a pressurized enclosure
Implementation Method 2
A flow- and pressure sensor system with a built-in relief valve and integrated purge controller that supervises both inlet and outlet of a pressurized enclosure
Implementation Method 3
A flow- and pressure sensor system with a built-in relief valve and integrated purge controller
Implementation Method 4
The enclosure is then pressurized to a positive air pressure relative to the atmospheric pressure. A positive pressure of about 0,5 mbar is all that is required.
Data Source
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AI summary
The invention refers to an explosion protection system for electrical apparatuses and machineries, such as manipulators or industrial robots, located in hazardous environments, i.e. environments containing explosive concentrations of inflammable gases, dusts or vapours, comprising means for applying internal pressurized air into an explosion proof enclosure and that has a purging system and electrical components, such as motors, relays, IC-boards, cables etc. The invention is achieved by, that a flow-and pressure sensor is arranged as an integrated unit and designed to stand high dynamic forces by having low inertia, balanced arrangement of moving parts and a movement guide, e.g. an axle with a support guide, with low friction.