Knocking Device Monitoring via Heat Exchanger Deflection

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional methods lack a reliable way to check the operational effectiveness of knocking devices in garbage incineration plants during boiler operation, leading to potential inefficiencies and maintenance challenges due to factors like wear, friction, and contamination.

Innovation Solution

A method involving the use of a knocking ram to deflect heat exchanger elements and measure the force required for deflection, as well as the attenuation behavior, to assess the operational capacity and degree of contamination, utilizing force and travel sensors to record and evaluate data for maintenance purposes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a knocking device is used to clean heat exchanger elements during boiler operation, then the running time and availability of the boiler are improved, but the operational effectiveness of the knocking device cannot be reliably checked, leading to potential inefficiencies due to wear, friction, and contamination

Engineering Contradiction:

Improveavailability of the boilerVSAvoidoperational effectiveness of knocking device

Core Design Contradiction:

ReliabilityVSDifficulty of detecting and measuring

Solution Approach 1:

The patent implements a feedback mechanism by measuring the travel of the heat exchanger element during knocking and comparing it to reference values. Sensors detect the actual position and movement of the heat exchanger element, providing continuous feedback on the knocking device's effectiveness. This allows operational parameters to be monitored and maintenance to be triggered when performance degrades due to wear, friction, or contamination.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces subjective mechanical assessment of knocking device performance with objective sensor-based measurements. Instead of relying on mechanical indicators or manual inspection, the system uses sensors to detect the travel and position of heat exchanger elements, converting mechanical behavior into measurable signals that can be automatically evaluated and compared against reference values.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If the knocking ram is actuated with high impact energy to ensure cleaning effectiveness, then the cleaning performance is improved, but the knocking ram may become severely worn or subjected to high friction in the guide

Engineering Contradiction:

Improvecleaning effectivenessVSAvoidservice life of knocking ram

Core Design Contradiction:

ProductivityVSDuration of action of moving object

Solution Approach 1:

The patent performs preliminary measurement of the heat exchanger element's travel before and during knocking operations. By establishing reference values in advance and comparing actual measurements against these references, the system can detect early signs of knocking ram wear or guide friction issues. This allows maintenance to be scheduled proactively before the knocking device fails completely, extending its service life while maintaining cleaning effectiveness.

Inventive Principle:

Principle #10Preliminary action

3Productivity

If the boiler operates for extended periods without maintenance to maximize productivity, then the operational efficiency is improved, but the heat exchanger elements become heavily contaminated with fly ash, reducing heat transfer efficiency

Engineering Contradiction:

Improveoperational efficiencyVSAvoidheat transfer efficiency

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent uses sensor feedback to continuously monitor the travel and position of heat exchanger elements during knocking operations. By comparing measured values against reference values established before commissioning, the system can detect when cleaning effectiveness decreases due to contamination buildup. This triggers timely maintenance interventions that restore heat transfer efficiency, allowing the boiler to operate at optimal productivity levels without prolonged degradation.

Inventive Principle:

Principle #23Feedback

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

Enables real-time assessment of knocking device performance, identifying issues such as friction, wear, and jamming, allowing for targeted maintenance and improving operational efficiency and availability of the boiler.

Implementation Method 1

the heat exchanger element (8a, 8b) is deflected out of its position of rest into a deflection position by means of the knocking ram (18)

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Implementation Method 2

the attenuation behavior of the heat exchanger element is determined, that is to say the travel of the heat exchanger element as a function of the time

Methodology Applied

Scientific EffectDamped vibration: Damping

Data Source

PatentUS8156819B2Method for checking a knocking device

Publication Date: 2012.04.17 VOL ROLL UMWELTTECHNIK AG

AI summary

A method is provided for checking a knocking device which is intended for cleaning a surface of a heat exchanger element arranged on an inside of a boiler housing of a garbage incineration plant. The knocking device has a knocking ram guided through a wall of the boiler housing and movable in a direction toward the inside of the boiler. The heat exchanger element is deflected out of its position of rest into a deflection position by the knocking ram, and the force required for deflecting the heat exchanger element and/or the attenuation behavior of the heat exchanger element released after deflection are/is determined.