Large Filter Module With Conveyor Positioning Unit

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Solution Overview

Problem

Current filter systems for high-volume applications, such as gas turbines, face challenges in shipping, installation, maintenance, and efficiency due to the need for multiple smaller filters, which increases costs and requires significant manual labor and time.

Innovation Solution

The introduction of a filter system with a larger filter module and a conveyor-based filter positioning unit that allows for easy mounting and removal of filters, enabling single large filters to be used, reducing manual handling and optimizing shipping and maintenance processes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If multiple smaller filters are used in filter houses, then the filtering capacity for high-volume applications is achieved, but the number of filters needed increases leading to increased shipping costs, installation time, and manual labor

Engineering Contradiction:

Improvenumber of filtersVSAvoidinstallation efficiency

Core Design Contradiction:

Quantity of substanceVSProductivity

Solution Approach 1:

The patent combines multiple smaller filters into a single large filter unit that can be transported and installed as one piece. This merging approach reduces the quantity of individual filter components from multiple separate filters to one integrated filter assembly, thereby decreasing shipping costs, reducing installation time, and minimizing manual labor requirements while maintaining the necessary filtering capacity for high-volume applications

Inventive Principle:

Principle #5Merging (Combining)

2Quantity of substance

If larger filter houses are designed to accommodate more filters, then the filtering capacity is increased, but the complexity of shipping, installation, and maintenance increases

Engineering Contradiction:

Improvefiltering capacityVSAvoidsystem complexity

Core Design Contradiction:

Quantity of substanceVSDevice complexity

Solution Approach 1:

The invention merges multiple filtering elements into a single large filter unit, which simplifies the overall system architecture. Instead of requiring a complex filter house structure designed to accommodate numerous individual filters with associated mounting brackets, seals, and access points, the system uses one integrated filter assembly that reduces structural complexity while achieving the same total filtering capacity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The large filter unit serves multiple functions that previously required separate components: filtration, structural support, and transportability. The filter is designed as a universal module that can be directly transported on flatbed trailers and mechanically positioned into place, eliminating the need for complex filter house structures and multiple installation components

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Productivity

If filters are made larger to reduce the number needed, then shipping and handling efficiency improves, but the ability to manually handle and install filters decreases

Engineering Contradiction:

Improveshipping efficiencyVSAvoidmanual handling ease

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The patent replaces manual mechanical handling with a mechanical positioning system. The large filter is designed with features that interface with mechanical positioning equipment, allowing it to be transported on flatbed trailers and mechanically lifted and positioned into the filter house. This substitution of manual operations with mechanical systems enables efficient shipping and installation of large filter units that would be impossible to handle manually

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention introduces a mechanical positioning system as an intermediary between the large filter and the installation location. This intermediary system includes features such as positioning rails, lifting mechanisms, or alignment guides that facilitate the transfer and installation of the large filter unit, bridging the gap between the filter's size and the capability to install it without excessive manual handling

Inventive Principle:

Principle #24Intermediary (Mediator)

4Quantity of substance

If more service technicians are deployed to install and service multiple filters, then the filtering capacity is maintained, but the cost and time of maintenance increases

Engineering Contradiction:

Improvefiltering capacityVSAvoidmaintenance time

Core Design Contradiction:

Quantity of substanceVSLoss of time

Solution Approach 1:

The patent combines multiple filters into one large filter unit, which directly reduces the number of maintenance operations required. Instead of having service technicians inspect, remove, and replace multiple individual filters, the system requires maintenance of a single integrated unit, thereby reducing maintenance time and the number of technicians needed while maintaining the same total filtering capacity

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS11207629B2Easily shipped and installed filter and filter house

Publication Date: 2021.12.28 PARKER INTANGIBLES LLC

AI summary

Filter systems, filters, and methods of managing filter systems are provided. The filter systems utilize large filters that are too large to be manually handled by service personnel. As such, the filter systems and methods utilize filter positioning units for handling the filters during maintenance intervals. Some systems include sensor for remotely monitoring the status of the filters and the information can be used to reverse pulse the filters as well as to indicate the end of the service life of the filters. The filters can be refurbished with new filter media.