Optical Nozzle Monitoring for Precise Centrifuge Clog Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Nozzle centrifuges face issues with nozzle clogging and diameter increase due to abrasion, leading to separation/clarification deterioration, and existing monitoring methods cannot accurately detect the exact location of clogged nozzles.
Innovation Solution
An optical nozzle monitoring device that includes a stroboscope, camera, and control unit for non-contact detection of blocked or partially blocked nozzles, using image recognition to identify nozzle changes and synchronize light pulses with drum rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If vibration monitoring is used to detect clogged nozzles, then the overall machine vibration can be monitored, but the exact position of the clogged nozzle within the drum cannot be determined
Solution Approach 1:
The monitoring system divides the drum into discrete measurement zones corresponding to individual nozzle positions. By synchronizing the camera capture with the drum rotation and comparing images at specific angular positions, the system segments the continuous rotation into measurable discrete states, enabling exact nozzle position identification without complex sensor arrays
Solution Approach 2:
The system creates optical copies (images) of the nozzle region at different positions during drum rotation. These image copies are then analyzed to detect changes in nozzle jet characteristics. The image copying approach simplifies the system compared to direct physical sensing at each nozzle position, as a single camera can capture multiple positional states through synchronized imaging
2Measurement precision
If sensors are positioned in the area of a nozzle jet with synchronization to detect exact location, then the exact location of a clogged nozzle can be detected, but the sensor becomes exposed to contamination from the nozzle jet
Solution Approach 1:
The patent introduces a protective barrier (such as a window or transparent barrier) between the sensor/camera and the nozzle jet. This intermediary allows the optical sensor to detect nozzle jet characteristics and clogged positions while being physically separated from the contaminating fluid, thus maintaining both detection precision and sensor cleanliness
Solution Approach 2:
The system replaces direct mechanical or physical contact sensing with optical imaging. Instead of having sensors directly in the jet path to detect clogging through physical interaction, the system uses cameras to capture optical images of the nozzle region, substituting mechanical sensing with optical detection to avoid contamination
3Measurement precision
If nozzle diameter increases due to abrasion, then the separation/clarification results deteriorate, but this change is difficult to detect
Solution Approach 1:
The system continuously captures images of the nozzle jet and compares them against reference images or establishes baseline characteristics. By analyzing changes in jet pattern, diameter, or flow characteristics in the captured images, the system provides feedback about nozzle wear and provides early warning before separation performance deteriorates significantly
Solution Approach 2:
The optical detection system can detect changes in the visual characteristics of the nozzle jet, such as changes in jet diameter, shape, or flow pattern, which manifest as variations in the captured images. These visual changes serve as indicators of nozzle abrasion and diameter increase without requiring direct physical measurement
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 rapid and accurate detection of nozzle blockages or diameter changes, allowing for automatic adjustment and replacement of affected nozzles, thereby maintaining separation efficiency and preventing machine imbalance.
Implementation Method 1
Emitting light pulses from the stroboscope onto the periphery of the rotating drum with the nozzles and adjusting the frequency of the light pulses based on a rotational frequency of the drum and synchronizing with it
Implementation Method 2
Capturing a synchronized and thus seemingly stationary image sequence of the drum, including a respective nozzle jet from the associated nozzle, by means of the camera
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A nozzle monitoring device (15) of a continuously operating nozzle centrifuge (1), in particular a nozzle separator, comprises a housing (2), in which a drum (3) which has a defined number of nozzles (8) on a periphery (3b) of the drum (3) is arranged so as to be rotatable about a vertical rotational axis (3a), wherein the nozzle monitoring device (15) has at least one sensor and a control unit (24). The nozzle monitoring device (15) is configured as an optical nozzle monitor with at least one stroboscope (19) and at least one camera (20), wherein the at least one camera (20) forms the at least one sensor. A nozzle centrifuge (1) with a nozzle monitoring device (15) of this type, and a method for monitoring nozzles (8) of a nozzle centrifuge (1), are provided.