Liquid Sample Pump with Integral Self-Cleaning Filter
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Solution Overview
Problem
Existing liquid samplers often face issues with filter clogging due to debris, dead space in sample mechanisms, and high costs and maintenance complexity of separate filter systems, which disrupt continuous sampling processes.
Innovation Solution
A sample pump with an integral self-cleaning filter element and a continuously flowing 'hot loop' design that uses turbulent liquid flow to sweep debris from the filter, minimizing dead space and reducing maintenance complexity and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate upstream filter system is used to prevent debris from entering the pump, then the pump is protected from debris, but the system becomes more expensive and more difficult to install and maintain
Solution Approach 1:
The filter element is integrated directly into the pump housing, combining the filter function and pump function into a single unit. This eliminates the need for separate upstream filter systems, reducing installation complexity and maintenance requirements while maintaining pump protection from debris
Solution Approach 2:
The integrated filter element serves multiple functions: it filters debris from the liquid sample, protects the pump mechanisms, and enables self-cleaning through the continuous hot loop flow. This multi-functionality reduces the need for separate components and simplifies the overall system
2Reliability
If a separate upstream filter element is used to prevent debris from entering the pump, then the pump is protected from debris, but the cost increases significantly
Solution Approach 1:
The filter element is manufactured as an integral part of the pump assembly, eliminating the need for separate filter purchases and installations. This integration reduces overall system cost while maintaining reliable pump protection from debris
Solution Approach 2:
The continuous hot loop flow automatically cleans the filter element, eliminating the need for manual cleaning or replacement by operators. This self-cleaning function reduces maintenance costs and extends filter life
3Reliability
If a strainer is placed between the process line and sampling pump, then debris is prevented from entering the pump, but the strainer is only cleaned during periodic purging, resulting in intermittent cleaning effectiveness
Solution Approach 1:
The hot loop provides continuous flow through the filter element, enabling constant self-cleaning action. This continuous cleaning process ensures the filter remains effective at all times, unlike periodic purging systems that allow debris accumulation between cleaning cycles
Solution Approach 2:
The filter element cleans itself continuously through the turbulent hot loop flow, which sweeps debris off the filter surface and carries it away. This self-cleaning mechanism operates automatically without requiring external intervention or periodic shutdowns for maintenance
4Reliability
If a heavy, expensive stand-alone filter element is used, then the filter provides robust debris removal, but the filter is difficult to install and maintain
Solution Approach 1:
The filter element is integrated into the pump housing as a single unit, making installation as simple as installing the pump itself. Maintenance is simplified because the filter can be accessed and replaced by simply removing the pump from the pipeline, eliminating the need for separate filter installation procedures
Solution Approach 2:
The pump assembly with integrated filter is designed as a modular unit that can be easily removed from the pipeline as a complete assembly. This segmentation allows the entire filter-pump unit to be quickly replaced without complex disassembly, improving maintenance ease
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 solution ensures continuous, efficient sampling with reduced downtime and maintenance costs by effectively cleaning the filter element and allowing quick replacement, maintaining a fresh sample flow without the need for expensive, separate filter systems.
Implementation Method 1
A continuously flowing loop of liquid through the sampler is sometimes called a 'hot loop' in the industry... uses turbulent liquid flow to sweep debris from the filter
Data Source
AI summary
In combination, a liquid sample pump and an integral self-cleaning filter element will elongate the maintenance interval for the pump which saves on time and labor costs. The filter element itself is small, economical to make and forms an integral part of the liquid sample pump. A flow passageway continuously directs turbulent liquid to the underside of the filter element to sweep debris from the filter element and return such debris to the pipeline. When it is necessary to service the liquid sample pump, it is quick and easy to remove and replace the filter element, which also saves on time and labor costs. A bleed valve assembly allows air to be bled from the sample pump prior to operation, enhancing seal life. An optional muffler assembly excludes insects from the inside of the sample pump, again elongating maintenance intervals. An optional return valve assembly allows unused sample to be returned to the pipeline, thus benefitting the environment. The filter element may be formed from a metal screen or a sintered metal disk.