Pressure Tank Condensation Separator for Autonomous Vehicle Sensors
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Solution Overview
Problem
Compressed air systems in vehicles experience condensation issues due to heat from air compressors, leading to moisture accumulation, which can impair the effectiveness of sensors, cameras, and brake systems, as conventional dryers struggle to keep up with temperature fluctuations and resulting excess moisture.
Innovation Solution
A pressure tank condensation separator with a vertically disposed wall and horizontally positioned shelves forming downflow and upflow paths, featuring drain holes and a purge valve, which directs compressed air through a torturous path to deposit condensation on shelves and expel it through drain holes, using injection molded plastic for a low-cost, efficient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a dryer is used to condition hot compressed air, then moisture removal is improved, but the dryer cannot keep up with large temperature shifts and resulting excess moisture
Solution Approach 1:
The tank is divided into multiple compartments by horizontal shelves, creating separate zones for condensation collection and air flow. This segmentation allows condensation to be trapped and removed independently from the main air flow path, enabling continuous moisture removal without limiting the air processing rate.
Solution Approach 2:
Condensation is extracted from the compressed air stream by directing it to collect on shelf surfaces and drain through dedicated drain holes at the bottom of each compartment. This separates the moisture removal function from the main air flow, allowing the system to handle large temperature shifts without compromising drying effectiveness.
2Temperature
If compressed air is cooled quickly to remove heat, then temperature control is improved, but condensation develops in the air system
Solution Approach 1:
The shelves are positioned to intercept condensation before it can accumulate in the main air flow path. By providing collection surfaces and drain holes in advance, the system prevents condensation from becoming a harmful factor in the compressed air system.
Solution Approach 2:
The rapid cooling that causes condensation is converted into a benefit by using the condensation collection surfaces to trap and remove moisture. The harmful condensation is redirected through drain holes to the purge valve, transforming the cooling-induced moisture problem into an effective moisture removal mechanism.
3Device complexity
If excess moisture is not removed from compressed air, then system simplicity is maintained, but sensors, cameras, and brake systems are impaired
Solution Approach 1:
The condensation separator integrates multiple functions into a single tank structure: condensation collection, moisture trapping, and purging. The shelves serve both as structural dividers and as condensation collection surfaces, while drain holes provide automatic moisture removal. This merged design protects sensors and brake systems without adding separate complex drying equipment.
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
Effectively separates and expels condensation from compressed air, maintaining system efficiency and longevity by ensuring peak performance of sensors, cameras, and brake systems through efficient moisture removal.
Implementation Method 1
condensation from compressed air is deposited on the surface of the shelves
Implementation Method 2
condensation flows through drain holes to a purge valve
Data Source
AI summary
A pressure tank condensation separator having an interior chamber forming a downflow path on a first side and an upflow path on a second side passing through horizontally positioned shelves; each shelf having at least one passageway positioned to cause a tortuous air path wherein moisture is separated and deposited on each shelf. The shelves are sloped, leading to drain holes for directing moisture collected to a purge valve. The removal of moisture is most beneficial to clean radar sensors, LIDAR and video cameras used on autonomous vehicles.