Optical Testing Device for Central Heating Inhibitor Level Detection

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Solution Overview

Problem

Central heating systems face challenges in maintaining optimal levels of corrosion inhibitors, leading to premature boiler failure and inefficiency due to corrosion and particulate contamination, as existing methods like magnetic filters do not prevent corrosion and require frequent manual topping up, which is costly and inefficient.

Innovation Solution

A testing device that automatically samples central heating system water to determine the level of corrosion inhibitors using optical properties, allowing for precise dosing and minimizing waste by integrating a sample chamber, piston for fluid control, and optical testing apparatus to measure inhibitor levels, optionally with a movable magnet to clear magnetic particles.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of substance

If a magnetic filter is used to remove particles from system water, then particulate contamination is reduced, but corrosion prevention is not achieved and particles continue to be generated

Engineering Contradiction:

Improveparticulate contaminationVSAvoidcorrosion prevention

Core Design Contradiction:

Loss of substanceVSReliability

Solution Approach 1:

The system segments the corrosion protection function into two distinct components: a magnetic filter that removes particles from circulation, and a separate dosing system that introduces corrosion inhibitor chemical into the system water. This segmentation allows each component to address its specific function effectively, with the filter handling particulate removal and the dosing system handling corrosion prevention.

Inventive Principle:

Principle #1Segmentation

2Reliability

If inhibitor chemical is added manually every twelve months, then corrosion protection is maintained, but unnecessary dosing occurs and costs increase

Engineering Contradiction:

Improvecorrosion protectionVSAvoidinhibitor chemical waste

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The system incorporates a sensor that continuously monitors the concentration of corrosion inhibitor chemical in the system water and provides feedback to the controller. The controller adjusts the dosing rate based on this feedback, increasing dosing when concentration is low and reducing or stopping dosing when concentration is sufficient. This closed-loop feedback control eliminates unnecessary dosing while ensuring adequate corrosion protection.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system enables self-service operation by automatically monitoring inhibitor levels and adjusting dosing without manual intervention. The sensor and controller work together to autonomously maintain optimal inhibitor concentration, eliminating the need for manual dosing schedules and allowing the system to adapt to changing conditions automatically.

Inventive Principle:

Principle #25Self-service

3Extent of automation

If continuous monitoring of inhibitor levels is implemented, then precise dosing control is achieved, but device complexity increases

Engineering Contradiction:

Improvedosing control precisionVSAvoidmonitoring system complexity

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The system replaces manual mechanical dosing with an automated electronic control system that uses optical or electrochemical sensors to monitor inhibitor levels. The sensor detects chemical concentration through optical absorption or electrochemical reactions, converting chemical information into electrical signals that the controller processes to automatically adjust dosing, thereby eliminating manual intervention while maintaining system reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Ensures the central heating system is consistently dosed with the correct inhibitor levels, reducing corrosion and particulate contamination, thereby extending boiler life and improving efficiency while minimizing inhibitor usage.

Implementation Method 1

optical testing apparatus including a light source and a detector, for measuring an optical property of the sample of central heating system water

Methodology Applied

Scientific EffectOptical absorption: Absorption (EM radiation)

Implementation Method 2

a piston which is movable within the sample chamber and has a sealing element on it which seals against the sample chamber

Methodology Applied

Scientific EffectHydraulic pressure: Pressure Gradient

Data Source

PatentUS11480523B2Chemical testing device with a sample chamber having a piston therein with a chamber sealing element thereon

Publication Date: 2022.10.25 ADEY HLDG

AI summary

A testing device (10) for testing the level of a selected chemical in central heating system water in a central heating system circuit comprises: a sample chamber (14) for holding a sample of central heating system water to be tested, the sample chamber (14) being connectable (12) to the central heating system circuit to allow fluid to pass between the central heating system circuit and the sample chamber (14); means (16) for controlling filling of the sample chamber (14) with central heating system water from the central heating system circuit, and emptying of the sample chamber (14); at least one valve (18) for isolating the sample of central heating system water from the heating circuit during testing; and optical testing apparatus including a light source (20) and a detector (22), for measuring an optical property of the sample of central heating system water isolated within the sample chamber (14) and thereby making a determination as to whether or not the level of the selected chemical in the water is greater than a predetermined threshold level.