Membrane Defect Inspection via Ultrasonic Echo Detection

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Solution Overview

Problem

Existing membrane defect inspection methods face challenges such as installation restrictions, reduced detection accuracy due to noise, and inability to automatically identify damaged membrane modules, particularly in water purification systems.

Innovation Solution

A membrane defect inspection method utilizing an ultrasonic sensor to detect reflected waves from bubbles in a gas detection piping system, allowing for individual identification of damaged membrane modules through gas injection and echo detection processes, with optional transparent piping for visual confirmation and image analysis.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If an ultrasonic flowmeter is used to detect bubbles, then bubble detection is enabled, but installation restrictions are imposed requiring a straight pipe of predetermined length

Engineering Contradiction:

Improvebubble detection capabilityVSAvoidinstallation flexibility

Core Design Contradiction:

Measurement precisionVSAdaptability or versatility

Solution Approach 1:

The detection system is segmented into multiple independent ultrasonic sensors positioned at different locations along the gas detection piping. Each sensor independently detects bubbles in its local section, eliminating the need for a single long straight pipe section and allowing flexible installation throughout the system.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces a control unit as an intermediary that collects data from multiple ultrasonic sensors and processes the information to identify damaged membrane modules. This intermediary system enables bubble detection without requiring direct line-of-sight or continuous straight piping between sensors.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Extent of automation

If vibration detection sensors are attached to each membrane module, then individual detection is enabled, but detection accuracy is degraded due to noise from external vibration and weak signals from firm structures

Engineering Contradiction:

Improveindividual membrane module detectionVSAvoiddetection accuracy

Core Design Contradiction:

Extent of automationVSMeasurement precision

Solution Approach 1:

The patent replaces mechanical vibration detection sensors with ultrasonic wave-based detection. Ultrasonic waves propagate through the gas detection piping and detect bubbles through acoustic reflection and transmission changes, eliminating mechanical contact with membrane modules. This substitution avoids mechanical vibration noise and provides higher detection accuracy while maintaining individual module identification capability through spatial positioning of ultrasonic sensors.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of operation

If transparent piping is used for visual inspection, then automatic detection becomes difficult, but visual confirmation is enabled

Engineering Contradiction:

Improvevisual inspection capabilityVSAvoidautomatic bubble detection

Core Design Contradiction:

Ease of operationVSExtent of automation

Solution Approach 1:

The patent merges transparent piping sections with ultrasonic sensor positioning. The transparent sections serve dual purposes: they allow visual inspection of bubble accumulation while also serving as acoustic transmission paths for ultrasonic detection. The control unit processes ultrasonic signals from sensors positioned at these transparent sections to automatically identify damaged modules, combining both visual and automated detection capabilities in a unified system.

Inventive Principle:

Principle #5Merging (Combining)

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 automated detection and identification of membrane damage or seal defects, improving detection accuracy and efficiency by using ultrasonic waves and visual confirmation of gas accumulation in membrane separation apparatuses.

Implementation Method 1

an echo detection process where an ultrasonic sensor including an ultrasonic transmitting section and an ultrasonic receiving section is brought into contact with an end portion of the straight pipe portion of the gas detection piping, and a reflected wave of an ultrasonic wave transmitted from the ultrasonic transmitting section is detected by the ultrasonic receiving section

Methodology Applied

Scientific EffectUltrasonic wave reflection: Echo

Implementation Method 2

a gas injection process where gas is injected into spaces opposite to the primary spaces or the secondary spaces communicating with the gas detection piping in the plurality of membrane modules while the gas detection piping is filled with water

Methodology Applied

Scientific EffectBubble formation and rise: Bubble

Data Source

PatentUS11890581B2Membrane defect inspection method and membrane defect inspection device

Publication Date: 2024.02.06 KUBOTA CORP

AI summary

A membrane defect inspection method is for a membrane module set including a plurality of membrane modules connected in parallel under a straight pipe portion of gas detection piping extending in a horizontal direction and communicating with primary spaces in the plurality of membrane modules to which raw water is supplied or secondary spaces. The method includes a gas injection process where gas is injected into spaces opposite to the primary spaces or the secondary spaces communicating with the gas detection piping while the gas detection piping is filled with water, and an echo detection process where an ultrasonic sensor is brought into contact with an end portion of the straight pipe portion of the gas detection piping, and a reflected wave of an ultrasonic wave transmitted from the ultrasonic sensor is detected.