Kiln Chimney Gas Flow Sensor with Automated Cleaning
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Solution Overview
Problem
Existing gas flow detection systems in ceramic kilns, such as Pitot tubes and hot-wire anemometers, deteriorate rapidly due to pollutant deposition, leading to unreliable measurements and inability to continuously monitor gas flow rates, especially when the chimney is clogged.
Innovation Solution
A device with resistance temperature detectors and a cleaning mechanism, comprising a piston and actuator system, is positioned in the outlet chimney to continuously measure gas flow rates by calculating speed and mass flow through thermal exchange coefficients, while effectively removing deposited impurities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If Pitot tubes or hot-wire anemometers are used to detect gas flow rate, then measurement capability is provided, but measurement reliability deteriorates rapidly due to pollutant deposition
Solution Approach 1:
The sensitive detection element (rod-shaped sensor) is extracted from direct contact with the polluted gas flow. Instead of placing the sensor directly in the gas stream where pollutants deposit, the system uses a suction device to draw gas through a probe, and the sensor measures flow characteristics in a controlled environment where deposition is minimized. This separation allows continuous reliable measurement without rapid deterioration from pollutant accumulation.
2Measurement precision
If probes are inserted inside chimneys for periodic sampling, then some measurement data is obtained, but continuous monitoring capability is lost
Solution Approach 1:
The system enables continuous measurement of gas flow rate through the chimney by using a rod-shaped sensor element that remains in position and continuously detects flow characteristics. The suction device operates continuously to draw gas through the probe, allowing uninterrupted monitoring of flow rate conditions, thereby maintaining continuous useful action for safety monitoring.
3Reliability
If cleaning mechanisms are added to remove pollutant deposition, then measurement reliability improves, but device complexity increases
Solution Approach 1:
The sensitive detection element is extracted from the polluted environment entirely, placed in a protected position where it measures flow characteristics through a probe system rather than direct exposure. This extraction eliminates the need for complex cleaning mechanisms while maintaining measurement reliability, as the sensor operates in a cleaner environment away from direct pollutant deposition zones.
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 device provides continuous, reliable gas flow rate measurements and detects clogging conditions, ensuring safe gas discharge without the need for periodic sampling, maintaining accuracy and operational efficiency.
Implementation Method 1
measuring the speed of the gas flow by means of the thermal exchange coefficient between the sensitive element and the gas flow
Implementation Method 2
a cleaning device for cleaning the sensitive elements
Data Source
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AI summary
A device (12) to detect the flowrate of the gases flowing out of a chimney (11) of a kiln (3) for the firing of ceramic products having a suction device (9) which directs the gases present in the kiln (3) towards the chimney (11); and wherein said device (12) is housed inside the chimney (11) and comprises a casing (13) provided with an axis (L) and having a head portion (16); and at least one sensitive element (24) having an end portion (28) housed inside the end portion (16) and which is subjected to a temperature variation proportional to the speed of the out-flowing gas flow (F); and a cleaning device (29) to clean the sensitive element (24) wherein an element (30) movable along the first axis (L) is operated by actuator means (31) so as to slide on the end portion (28) and to remove the pollutants that have deposited there.