Piston Pump Pressure Damping via Indirect Fill Control
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Solution Overview
Problem
Piston thick matter pumps experience pressure fluctuations during the switching phase between suction and pressure strokes, leading to material fatigue and premature failure due to brief interruptions in material flow and pressure drops, which existing damping systems like diaphragm dampers and air tanks fail to address effectively, especially with abrasive materials.
Innovation Solution
A control device that maintains the fluid fill level in a container connected to the delivery line based on operating parameters, using a pressure sensor and electronic processing unit to determine a pressure ratio or mean value of delivery pressure, and automatically refills the fluid to maintain optimal damping, reducing energy consumption and wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a direct fill level determination sensor (e.g., vibrating fork sensor) is installed in the container, then the fill level can be measured directly, but the sensor is exposed to high wear due to abrasive conveyed materials
Solution Approach 1:
The patent introduces an intermediary measurement approach by using a pressure sensor located in the delivery line rather than directly in the container. The pressure sensor measures delivery pressure, which serves as an indirect indicator of the fluid volume in the container. This mediator approach allows fill level determination without exposing sensors to abrasive materials, resolving the contradiction between measurement precision and sensor durability.
2Reliability
If excessive fluid is provided to ensure adequate damping, then pressure fluctuations are reduced, but operating costs increase due to unnecessary fluid provision
Solution Approach 1:
The patent implements a feedback control system where the pressure sensor continuously monitors delivery pressure, and the control device adjusts the fluid volume in the container based on measured pressure values. The system compares actual pressure against target pressure ranges and dynamically refills or maintains fluid volume accordingly. This feedback mechanism ensures adequate damping effectiveness while avoiding excessive fluid provision, thereby reducing energy consumption for fluid compression.
3Reliability
If the container is continuously refilled to maintain optimal damping, then pressure fluctuations are minimized, but energy consumption increases
Solution Approach 1:
The patent employs periodic refilling action controlled by pressure measurements rather than continuous refilling. The control device monitors delivery pressure periodically and triggers refilling only when pressure values indicate fluid volume has decreased below optimal levels. This periodic action maintains damping consistency while significantly reducing energy consumption compared to continuous refilling operations.
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 effectively reduces pressure fluctuations, minimizing mechanical loads and extending the lifespan of the delivery line by maintaining optimal damping while reducing the need for excessive fluid provision, thus enhancing operational efficiency and cost-effectiveness.
Implementation Method 1
at least partially filled with a compressible fluid for the pulsating reception and delivery of conveyed material during pumping operation of the thick matter pump with alternating compression and expansion of the fluid
Implementation Method 2
damping pressure fluctuations in a delivery line of a piston thick matter pump
Data Source
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AI summary
The invention relates to a device and to a method for damping pressure fluctuations in a delivery line (14) of a piston thick-matter pump (10), comprising at least one container (16), which communicates with the delivery line and is at least partially filled with a compressible fluid, for receiving and discharging conveyed material (12) during the pumping operation of the thick-matter pump (10) with alternating compression and expansion of the fluid. According to the invention, in order to realize economical and reliable damping, a control apparatus (22) for the degree of fluid filling in the container (16) in dependence on operating parameters during the pumping operation is proposed, the control apparatus comprising at least one pressure sensor (20) for determining the delivery pressure, which pressure sensor is preferably arranged in the container (16) or in the delivery line (14), and comprising an electronic computing unit, which is intended and suitable for determining and storing a pressure ratio V between delivery pressure values during a working cycle of the thick-matter pump (10) and during a switch-over phase between the working cycles of the piston of the thick-matter pump or a mean value M of the delivery pressure over a time interval during the switch-over phase as a measure of the effectiveness of the damping.