Membrane Pump Leakage Detection via Vacuum Insulation
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Solution Overview
Problem
In the food processing industry, particularly in homogenization, existing high-pressure pumps face challenges in preventing hydraulic oil leakage from piston seals into the product, which can contaminate the product and lead to health issues and product losses, while also being costly and inefficient in terms of operational costs and resource usage.
Innovation Solution
A membrane pump system is introduced, featuring a first and second membrane with a vacuum interior space between them, equipped with a resistance meter to detect fluid leakage due to membrane rupture, and optionally a control unit to trigger alarms, ensuring immediate and robust leakage detection without the need for steam barriers, thus reducing operational costs and enhancing food safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If piston seals are used to prevent hydraulic oil leakage, then product contamination is reduced, but detection capability of leakage is insufficient
Solution Approach 1:
The patent introduces a detection fluid as an intermediary substance between the hydraulic oil chamber and product chamber. This fluid serves dual purposes: it acts as a barrier to prevent hydraulic oil contamination while enabling leakage detection through its distinct electrical properties. The detection fluid contains conductive particles that allow electrical conductivity measurement, creating a mediator system that both protects and signals.
Solution Approach 2:
The patent replaces traditional mechanical leakage detection methods with an electrical field-based detection system. Instead of relying on mechanical sensors or pressure changes, the system uses electrical conductivity measurements to detect the presence of detection fluid in the product chamber, indicating membrane rupture or seal failure.
2Object-affected harmful factors
If food graded oils are used as precautionary measure, then health risk is reduced, but product properties are negatively affected when oil leaks
Solution Approach 1:
The detection fluid acts as an intermediary barrier between hydraulic oil and product. It prevents direct contact between product and both hydraulic oil and membrane, creating a protective buffer zone that maintains product integrity while enabling detection of system failures.
Solution Approach 2:
The patent changes the electrical parameter (conductivity) of the fluid in the product chamber by introducing conductive particles in the detection fluid. This parameter change enables electrical detection of leakage without affecting the food safety or quality of the product, as the detection fluid itself is food-grade.
3Reliability
If double piston seals with water or steam are used, then lubrication and contamination prevention are improved, but operational costs increase
Solution Approach 1:
The detection fluid system is self-sufficient and does not require external utilities for operation. Unlike steam or water systems that need heating, pumping, and drainage infrastructure, the detection fluid passively provides both lubrication and detection functions through its inherent electrical properties, eliminating the need for additional energy-consuming equipment.
Solution Approach 2:
The detection fluid serves multiple functions simultaneously: it lubricates the piston seals, prevents contamination, and enables leakage detection through electrical conductivity measurement. This multi-functional approach replaces separate systems for lubrication and detection, reducing operational complexity and energy consumption.
4Object-affected harmful factors
If steam barriers are used to prevent re-infection, then product safety is improved, but capital expenditure and operational costs increase
Solution Approach 1:
The patent replaces thermal-based steam barriers with an electrical field-based detection system. Instead of using steam to prevent re-infection, the system uses electrical conductivity measurements to detect membrane failures, allowing for immediate shutdown and preventing contamination without requiring complex steam generation and distribution infrastructure.
Solution Approach 2:
The detection fluid serves as an intermediary that eliminates the need for steam barriers. It provides a physical and chemical barrier against contamination while simultaneously enabling detection of system failures through its electrical properties, replacing the need for separate steam sterilization systems.
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 membrane pump system provides a reliable, cost-efficient, and immediate indication of membrane rupture, reducing the risk of hydraulic oil contamination and product losses, while minimizing operational costs and environmental impact by eliminating the need for steam barriers.
Implementation Method 1
A membrane interior space with vacuum is formed between the first membrane and the second membrane
Implementation Method 2
a resistance meter which is configured to detect a resistance between the first element and the second element
Data Source
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AI summary
The invention relates to a membrane pump (700) comprising a first membrane (701) and a second membrane (702). A membrane interior space (704) with vacuum is formed between the first membrane (701) and the second membrane (702). The membrane interior space (704) comprises a first element (705) and a second element (707), wherein the first element (705) and the second element (707) are separated and electrically insulated by the vacuum in the interior space (704). The membrane pump (700) further comprises a resistance meter (709) which is configured to detect a resistance between the first element (705) and the second element (707) arising from a fluid leakage into the membrane interior space (704) due to rupture of the first membrane (701) and/or the second membrane (702).