Landfill Pump Float Slot and Replaceable Sleeve Design
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Solution Overview
Problem
Existing landfill leachate and liquid level control pumps face issues with stiction due to corrosion and solids adhesion, leading to increased maintenance needs and reduced efficiency, particularly due to the abrasion of discharge tube surfaces and the susceptibility of stainless steel 'E' clips to corrosion and damage.
Innovation Solution
A pneumatically driven liquid level control pump design featuring a polymeric float with a through slot and a removable discharge tube sleeve, along with a pivoting lever assembly and check valves, reduces stiction by minimizing frictional contact and allowing for easy cleaning and replacement of components, thereby enhancing the pump's resistance to contaminants and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a metal discharge tube with protrusions is used to reduce contact area, then stiction forces are reduced, but the metal surface is susceptible to corrosion and abrasion leading to increased solids adhesion
Solution Approach 1:
The patent employs a sacrificial polymeric coating on the discharge tube that is intentionally designed to be replaceable. This coating provides a smooth, non-corrosive surface during its service life, reducing stiction and solids adhesion. When the coating becomes worn or contaminated beyond a certain point, it is removed and replaced, restoring the discharge tube to like-new conditions without replacing the entire metal tube assembly.
Solution Approach 2:
The discharge tube is constructed as a composite structure combining a metal base tube with a polymeric coating layer. The metal provides structural strength and durability, while the polymeric coating provides a smooth, corrosion-resistant surface that minimizes friction and prevents solids adhesion. This composite approach allows each material to contribute its superior properties to the overall system.
2Device complexity
If stainless steel 'E' clips are used for air control, then the pump mechanism is simple, but the clips are susceptible to corrosion and subtle damage requiring replacement
Solution Approach 1:
The stainless steel 'E' clips are designed as sacrificial, easily replaceable components. They perform the simple function of controlling air flow in the pneumatic actuation system but are intentionally made vulnerable to corrosion and damage. When these clips fail, they are quickly replaced without affecting other parts of the pump, maintaining system simplicity while ensuring reliability through easy maintenance.
Solution Approach 2:
The vulnerable 'E' clips are extracted as separate, independent components from the main pump body. This allows them to be individually replaced without disassembling or damaging other parts of the pump mechanism. The clips are taken out as sacrificial elements that protect the more complex and expensive pump components from corrosion and damage.
3Manufacturing precision
If the discharge tube surface becomes rough from abrasion, then solids adhesion increases, but cleaning becomes more difficult
Solution Approach 1:
Instead of attempting to clean and restore a roughened discharge tube surface, the patent employs a replaceable polymeric coating that maintains smoothness throughout its service life. When the coating becomes rough or contaminated, it is removed and replaced with a new coating, restoring the smooth surface without requiring complex cleaning procedures or specialized equipment.
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 design significantly reduces the buildup of solids, minimizes friction, and simplifies maintenance, resulting in improved operational efficiency and extended service life by reducing corrosion and adhesion issues, while eliminating the need for stainless steel 'E' clips.
Implementation Method 1
A liquid level control pump is provided which is adapted to be lowered into contact with a fluid collecting within a wellbore and being in communication with an external pressurized fluid source
Implementation Method 2
The float is arranged coaxially around the discharge tube and is moveable along the discharge tube towards the first and second ends. The float moves towards the first end as the area within the pump casing fills with the fluid
Implementation Method 3
The first check valve is disposed at the first end for controlling a flow of the fluid within the discharge tube to one direction only, that being out from the first end of the discharge tube. The second check valve is disposed at the second end for limiting the flow of fluid to one direction only, that being from the pump casing into the discharge tube
Data Source
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AI summary
A liquid level control pump especially well adapted for use in landfill wells is disclosed. The pump makes use of a pump casing, a discharge tube, a control rod, first and second check valves, a float and a pivoting lever assembly for controlling the application of a pressurized fluid from an external pressurized fluid source. In one aspect the float may include a through slot which allows the control rod to pass therethrough and which helps to reduce the chance of the float hanging due to an accumulation of solids between the control rod and the float. In another aspect a removable and replaceable discharge tube sleeve may be included.