Modular condensate removal system, modules and corresponding installation and maintenance methods
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Solution Overview
Problem
Current condensate removal systems face challenges in industrialization, installation complexity, and maintenance due to the need for diverse product types and configurations, leading to increased production time, storage complexity, and high costs.
Innovation Solution
A modular condensate removal system comprising a pumping, detection, and control module, allowing for flexible configurations such as aligned, two-piece, and one-piece setups, with reversible attachments and compact designs to adapt to various installation environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional fixed-configur ation condensate removal systems are used, then installation is simplified for specific applications, but product diversity and storage complexity increase
Solution Approach 1:
The condensate removal system is divided into separate functional modules: a pump module and a detector module. Each module can be independently manufactured, stored, and installed. The pump module contains the pump and housing, while the detector module contains the water level detector and associated electronics, allowing for standardized production and reduced inventory complexity.
Solution Approach 2:
The modular design creates universal components that can be used across multiple installation configurations. The same pump module and detector module can be combined in different ways (aligned, L-shaped, remote) to suit various application requirements, eliminating the need for multiple specialized product variants.
2Adaptability or versatility
If multiple product types are maintained for different applications, then adaptability increases, but maintenance complexity and time increase
Solution Approach 1:
By segmenting the system into standardized modules, maintenance personnel only need to be trained on a limited set of component types rather than multiple complete product variants. Faulty components can be quickly identified and replaced at the module level.
Solution Approach 2:
The detector can be extracted as a separate removable module from the pump assembly. This allows the detector to be independently replaced or upgraded without replacing the entire pump system, simplifying maintenance and reducing downtime.
3Adaptability or versatility
If detector is placed at distance from pump with wired connection, then installation flexibility improves, but system complexity increases
Solution Approach 1:
The system separates the detector and pump into independent modules that can be positioned at different locations. Wired connections are provided through the modular interfaces, enabling flexible installation configurations including remote detector placement while maintaining manageable system complexity through standardized connection points.
Data Source
AI summary
A condensate removal system including at least three independent modules: a pumping module, a detection module and a control module. The pumping module includes a pump. The detection module includes a tank for receiving condensates and is capable of detecting at least two levels of condensates in the tank. The control module includes electronics for controlling the pump based on the levels of condensates. Each of the modules includes hydraulic and/or electrical connections to at least one other module, and at least two of the modules include a reversible attachment to one another, so that the at least three modules can be connected according to at least two configurations among: an aligned configuration; a two-piece configuration; or a one-piece configuration.